Bolter

ABSTRACT

A drilling and bolting rig includes a carousel rotatable about a carousel axis and including a plurality of stations configured to support a plurality of consumables, one or more actuators, and a position sensor coupled to the carousel. The one or more actuators are configured to rotate the carousel about the carousel axis. The drilling and bolting rig further includes an electronic processor coupled to the one or more actuators and the position sensor. The electronic processor is configured to detect, using the position sensor, a rotational position of the carousel, and rotate, using the one or more actuators, the carousel based on the rotational position of the carousel.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a divisional of prior-filed, co-pending U.S. patentapplication Ser. No. 17/492,521, filed Oct. 1, 2021, which claimspriority to U.S. Provisional Patent Application No. 63/086,392, filedOct. 1, 2020. The entire contents of these applications are incorporatedherein by reference.

FIELD

The present disclosure relates to a drill rig, and more particularly toan underground drill rig.

In underground mining and construction, drill rigs perform drilling andbolting operations. One common use for a drill rig is to reinforce aroof or wall section with a reinforcement member (e.g., a rebar bolt).In order to perform drilling operations, the drill rig requires a supplyof consumables.

SUMMARY

The disclosure provides, in one aspect, a drilling and bolting rig forperforming drilling and bolting operations. The drilling and bolting rigincludes a magazine for storing a consumable, a feed supporting a drillhead for movement relative to a work surface, and a loader configured toretrieve the consumable from the magazine and load the consumable intothe drill head. The loader includes an arm operable to engage theconsumable. The arm is supported for both rotational and translationalmovement.

In some aspects, the consumable is at least one of a plurality ofconsumables, and the plurality of consumables includes at least two of adrill bit, a resin cartridge, a resin injector, a first bolt, a secondbolt, an adaptor, and an extension rod.

In some aspects, the magazine includes a carousel rotatable about afirst axis to selectively place the consumable into a loading positionin which the consumable can be retrieved by the loader, and the carouselis rotatable about the first axis in response to a first actuator.

In some aspects, the loader includes a loading arm rotatable about asecond axis that is offset relative the first axis, and the loading armis configured to remove the consumable from the loading position on thecarousel and move the consumable to position an end of the consumable inthe drill head.

In some aspects, the feed is extendable along a drill axis orientedparallel relative to at least one of the first axis and the second axis.

In some aspects, the drive unit is operable to apply the desiredconsumable to the work surface, and the loading arm is rotatable aboutthe second axis to retrieve the consumable from the drill head.

In some aspects, the magazine includes a carousel rotatable about anaxis, and a distance between the drill head and an axis of rotation ofthe loading arm is equal to a distance between the axis of rotation ofthe loading arm and the axis about which the carousel rotates.

In some aspects, rotation of the carousel is automated by a controllerto define at least a portion of a drill cycle in which the consumableretrieved from the loading position on the carousel is replaced withanother consumable by rotating the other consumable into the loadingposition.

In some aspects, rotation of the loading arm is automated by thecontroller and selectively replaces the one consumable with the otherconsumable.

In some aspects, the one consumable includes a drill bit and the otherconsumable includes a resin cartridge.

In some aspects, another consumable includes a bolt, and the loading armis automated by the controller to transfer the bolt to the drive unit,the drive unit inserting the bolt into resin in the work surface in abolt cycle.

In some aspects, the drill cycle, the resin cycle, and the bolt cycleare automated by the controller such that the manual interaction of ahuman operator is unnecessary for operation of the underground miningand construction rig.

In some aspects, the carousel supports each of the plurality ofconsumables at a predetermined position, and the carousel includes afeature aligned with one of the plurality of consumables, the featureengaging a bypass actuator when the one of the plurality of consumablesis aligned with the loading arm to modify a path of movement of theloading arm

In some aspects, the feature is a protrusion positioned on a portion ofthe carousel and the bypass actuator is coupled to a valve, actuation ofthe valve causing fluid flow to bypass a hydraulic circuit associatedwith an extension of the loading arm.

In some aspects, the loader includes a support member, a loading armsupported for rotation relative to the support member, and a grippersupported on the loading arm, the support member including a first port,the loading arm including a second port in fluid communication with thefirst port while the loading arm rotates to provide pressurized fluid toan actuator, the actuator operating at least one of the loading arm andthe gripper.

In some aspects, the loader includes a support member, a loading armsupported for rotation relative to the support member, and a grippersupported on the loading arm, the support member including a mast, asleeve slidably supported on the mast, a key extending through thesleeve and engaging the mast to guide sliding movement of the loader,the support member further including a retainer for maintaining the keyin engagement with the mast, the retainer including a first portionextending around a first peripheral portion of the sleeve and a secondportion extending around a second peripheral portion of the sleeve.

The disclosure provides, in another aspect, a drilling and bolting rigfor performing automated drilling and bolting operations. The drillingand bolting rig includes a magazine supporting a consumable, a feedmoveably supporting a driver relative to a work surface, a loaderincluding an arm configured to transfer the consumable from the magazineto the driver, and a washer loader configured to transfer a washer froma washer store to be positioned adjacent the consumable. The washerincludes an aperture configured to receive the consumable therethrough.

In some aspects, the washer store is arranged in a refillable stack.

In some aspects, the washer loader includes a carrier arm having aportion configured to magnetically engage a single washer from thewasher store.

In some aspects, the drilling and bolting rig for performing automateddrilling and bolting operations further includes a support configured tomaintain the washer in a predetermined position relative to theconsumable as the consumable and washer are transferred to the driver.

In some aspects, the washer loader includes a carrier arm, furtherincluding a protrusion for guiding the washer as the consumable andwasher are transferred to the driver, the protrusion extending from thecarrier arm.

In some aspects, the washer loader may optionally bypass placement of atleast one washer of the washer store when the consumable is transportedto driver by the loader.

In some aspects, the consumable is one of a plurality of consumablessupported by the magazine, the plurality of consumables including atleast two of a drill bit, a resin cartridge, a resin injector, a firstbolt, a second bolt, an adaptor, and an extension rod.

In some aspects, the drilling and bolting rig for performing automateddrilling and bolting operations further includes a controller configuredto automate operation of the magazine, the loader, the feed, and thewasher loader such that the bit, bolt, and the washer are transported tothe work surface without manual interaction of a human operator.

In some aspects, the washer loader includes a carrier arm configured toengage the washer and a carrier actuator supporting the carrier arm, thewasher loader further including a guide groove coupled to one of thecarrier arm and the carrier actuator, and a guide coupled to the otherof the carrier arm and the carrier actuator, the guide received withinthe guide groove, wherein operation of the actuator causes the guide tomove along the guide groove to move the carrier arm along apredetermined path.

In some aspects, at least a portion of the guide groove is curvilinear,movement of the guide in the guide groove causing rotation of thecarrier arm in response to operation of the carrier actuator.

In some aspects, the guide groove includes a first groove portion and asecond groove portion releasably secured relative to the first grooveportion, wherein a position of the first groove guide portion relativeto the second groove guide portion may be adjusted, thereby adjusting atleast one of a starting position and an ending position of the carrierarm.

In some aspects, the washer loader includes a carrier arm configured toengage the washer, the carrier arm being rotatable about an axis by afirst carrier actuator and moveable in a radial direction relative tothe axis by a second carrier actuator.

In some aspects, the washer loader includes a carrier arm configured toengage the washer, the carrier arm being extendable along a first axisby a first carrier actuator and moveable along a second axis offsetrelative the first axis by a second carrier actuator, and the carrierarm is moveable along at least one of the first axis and the second axisto move the washer.

The disclosure provides, in another aspect, a drilling and bolting rigfor performing automated drilling and bolting operations. The drillingand bolting rig includes a magazine including a mast, a carouselrotatable relative the mast about a carousel axis and including aplurality of stations, at least some of the stations configured tosupport a consumable, the plurality of stations being positioned aroundthe mast, and an actuator positioned within the mast, the actuatorconfigured to rotate the carousel about the carousel axis. The drillingand bolting rig includes a magazine further including a loaderconfigured to retrieve at least one of the consumables from the magazineand transfer the consumable into a drive unit.

In some aspects, the drilling and bolting rig further includes a feedsupporting the drive unit for movement relative to the work surfacealong a longitudinal direction, and the longitudinal direction isparallel to the carousel axis.

In some aspects, the drilling and bolting rig further includes acontroller configured to operate the loader to retrieve the consumablefrom the magazine and transfer the consumable to the drive unit, andconfigured to operate the drive unit and feed to insert the consumableinto a work surface without requiring manual interaction of a humanoperator.

The disclosure provides, in another aspect, a magazine for storingconsumables for a drilling and bolting rig. The magazine includes amast, a carousel supported for rotation relative the mast about an axis,and a clip supported on the carousel. The clip is configured to retain aconsumable. The clip is removably coupled to the carousel.

In some aspects, the magazine further includes an actuator for rotatingthe carousel about the axis. The actuator is positioned within the mast.

In some aspects, the clip includes a biasing finger providing a biasingforce configured to retain the consumable within a slot, the biasingfinger being deformable in response to a force exerted on the finger topermit removal of the consumable from the slot.

In some aspects, the clip is one of a plurality of clips, and thecarousel includes at least one rack configured to support the pluralityof clips, the clip being removably coupled to the rack by a fastener.

In some aspects, the plurality of clips are arranged circumferentiallyabout the axis.

In some aspects, the clip is configured to engage a consumable of afirst type, the clip being replaceable with a clip configured to engagea consumable of a second type.

In some aspects, a portion of the clip configured to engage theconsumable includes a wear member along which the consumable may slideas the consumable is inserted into and removed from the clip.

In some aspects, the carousel is rotatable to position the clip in aloading position in which a loader is configured to engage theconsumable. The loader is configured to remove the consumable from theclip and transport the consumable to a feed.

The disclosure provides, in another aspect, a drilling and bolting rigthat includes a drill head for driving a consumable into a work surface,a feed supporting the drill head for movement relative to a worksurface, a hydraulic circuit including, at least one auxiliary flowcontrol valve for selectively controlling flow of pressurized fluid toone of a first hydraulic component and a second hydraulic component, anda main flow control valve for controlling flow of pressurized fluid tothe at least one auxiliary flow control valve. The at least oneauxiliary flow control valve and the main flow control valve are movablebetween a first configuration and a second configuration. Pressurizedfluid is provided to operate the first hydraulic component while the atleast one auxiliary flow control valve and the main flow control valveare in the first configuration. Pressurized fluid is provided to operatethe second hydraulic component while the at least one auxiliary flowcontrol valve and the main flow control valve are in the secondconfiguration.

In some aspects, the first hydraulic component is operable to performone of the following functions: index tilt the feed in a left/rightdirection; index tilt the feed in a fore/aft direction; rotate aconsumable store; raise/lower a loading arm for loading the consumable;rotate the loading arm; open/close jaws for gripping the consumable; andoperate a washer loading arm for loading a washer.

In some aspects, the second hydraulic component is operable to performanother one of the following functions: index tilt the feed in aleft/right direction; index tilt the feed in a fore/aft direction;rotate a consumable store; raise/lower a loading arm for loading theconsumable; rotate the loading arm; open/close jaws for gripping theconsumable; and operate a washer loading arm for loading a washer.

In some aspects, the first hydraulic component is operable to actuate aportion of the feed, and the second hydraulic component is operable toactuate a portion of a magazine.

In some aspects, the first hydraulic component is operable to actuate aportion of the feed, and the second hydraulic component is operable toactuate a portion of a loading arm for transferring the consumable froma magazine to the drill head.

In some aspects, the drilling and bolting rig further includes a loaderconfigured to retrieve the consumable from a magazine and load theconsumable into a drill head. The loader includes an arm operable toengage the consumable. The arm is supported for both rotational andtranslational movement.

In some aspects, the hydraulic circuit further includes a functionselect line selectively providing pressurized fluid to move the at leastone auxiliary flow control valve between the first configuration and thesecond configuration.

In some aspects, function select line may be toggled between a firstpressure condition in which the at least one auxiliary flow controlvalve is in a first position and a second pressure condition in whichthe at least one auxiliary flow control valve is in a second position.

In some aspects, the at least one auxiliary flow control valve includesa first auxiliary flow control valve associated with the first hydrauliccomponent and a second auxiliary flow control valve associated with thesecond hydraulic component. Each of the first auxiliary flow controlvalve and the second auxiliary flow control valve are moveable between afirst position and a second position.

In some aspects, the first auxiliary flow control valve and the secondauxiliary flow control valve are neutrally biased toward the firstposition in which pressurized fluid is directed to operate the firsthydraulic component, and movement of the first auxiliary flow controlvalve and the second auxiliary flow control valve to the second positioncauses pressurized fluid to be directed to operate the second hydrauliccomponent.

In some aspects, the first hydraulic component is part of a firstsub-circuit and the second hydraulic component is part of a secondsub-circuit that is arranged in parallel with the first sub-circuit.

In some aspects, the main flow control valve is a three-position,solenoid-actuated, electronically-controlled valve, and the at least oneauxiliary flow control valve is a two-position, hydraulic valve.

In some aspects, the at least one auxiliary flow control valve is biasedtoward a neutral position in which pressurized fluid is directed tooperate the first hydraulic component.

The disclosure provides, in one aspect, a drilling and bolting rigcomprising: a carousel rotatable about a carousel axis and including aplurality of stations configured to support a plurality of consumables;one or more actuators configured to rotate the carousel about thecarousel axis; a position sensor coupled to the carousel; and anelectronic processor coupled to the one or more actuators and theposition sensor. The electronic processor is configured to detect, usingthe position sensor, a rotational position of the carousel; and rotate,using the one or more actuators, the carousel based on the rotationalposition of the carousel.

In some aspects, the position sensor is a magnetic rotary encoder.

In some aspects, the position sensor includes a Hall-sensor.

In some aspects, the position sensor is an intrinsically safe positionsensor and includes an encoder housing, and the encoder housing is fixedto the carousel such that the Hall-sensor extends into the carousel andis in close proximity to a magnet attached to the carousel.

The disclosure provides, in another aspect, a control panel for a drillrig of an automatic bolter comprising: a keypad including an overlay; aplurality of buttons provided on the keypad and configured to controlvarious functions of the drill rig; a plurality of force sensingresistor material corresponding to the plurality of buttons providedbelow the overlay, wherein a drop in resistance of a force sensingresistor material of the plurality of force sensing resistor materialcorresponds to a force applied to the corresponding button of theplurality of buttons; and a display and a speaker provided on thekeypad. The plurality of buttons are divided between a plurality ofcontrol button banks, each control button bank of the plurality ofcontrol button banks corresponding to a particular component of thedrill rig.

In some aspects, the overlay has a thickness between 0.15 millimeters(mm) and 3 mm.

In some aspects, the control panel further includes a first lightemitting diode (LED) and a second LED corresponding to a first operationand a second operation of the drill rig. The first LED provides a statusindication of the first operation, and the second LED provides a statusindication of the second operation. The first LED and the second LED aremulticolor LEDs.

In some aspects, the control panel further includes a first landmarkprovided between a first control button bank and a second control buttonbank of the plurality of control button banks.

In some aspects, the control panel further includes a second set oflandmarks provided around a first button and a second button of thefirst control button bank.

In some aspects, the control panel further includes a third landmarkaround a third button of the first control button bank and a fourthbutton provided below the third button without a landmark.

In some aspects, the first landmark, the second set of landmarks and thethird landmark are raised landmarks.

In some aspects, the second set of landmarks and the third landmark areengraved landmarks.

In some aspects, the first button is provided above a second button,wherein the second set of landmarks are directional landmarks indicatingupwards and downwards directions around the first button and the secondbutton respectively, wherein the first button and the second buttoncontrol an upward and downward movement respectively of a component ofthe drill rig.

In some aspects, the third landmark is a directional landmark indicatingan upwards direction around the third button, wherein the third buttonand the fourth button control a clockwise and counterclockwise rotationrespectively of a component of the drill rig.

In some aspects, the control panel further includes a bounding boxprovided around the first control button bank.

In some aspects, the control panel further includes a connector thatallows a connection of a second control panel configured to control theautomatic bolter from a distance.

The disclosure provides, in another aspect, a method for fully automatedoperation of a drill rig for an automatic bolter, the method comprising:receiving, with a controller of the drill rig, a full automation moderequest; automatically performing, using the drill rig, a drillingoperation on a working surface in response to receiving the fullautomation mode request; automatically performing, using the drill rig,a resin injection operation on the working surface subsequent to thedrill operation; and automatically performing, using the drill rig, abolting operation on the working surface subsequent to the resininjection operation

In some aspects, the method further includes determining, using thecontroller, whether an error has occurred during one of the automaticdrilling operation, the automatic resin injection operation, and theautomatic bolting operation; directing a user to manually perform anoperation when the error has occurred; receiving, via a control panel,user input corresponding to the operation; and performing, using thecontroller, the operation based on user input.

In some aspects, the method further includes determining, using thecontroller, whether the error is resolved; generating, using thecontroller, an alert indicating that the drill rig is ready forautomated operation; receiving, via the control panel, an input toresume automated operation; and resuming, using the controller, one ofthe drilling operation, the resin injection operation, and the boltingoperation.

In some aspects, performing one of the automatic drilling operation, theautomatic resin injection operation, and the automatic bolting operationincludes rotating the carousel to one of a drill loading position, aresin cartridge loading position, a bolt loading position, and anadapter loading position.

In some aspects, rotating the carousel to one of the drill loadingposition, the resin cartridge loading position, the bolt loadingposition, and the adapter loading position further includes controlling,using the controller, a first actuator based on rotation positionsignals received from an intrinsically safe rotary encoder of thecarousel.

The disclosure provides, in another aspect, a drill rig for an automaticbolter comprising: a carousel rotatable about an axis and configured tostore one or more consumables; a drill head configured to apply the oneor more consumables to a working surface; and a loading assembly. Theloading assembly includes a loading arm configured to move laterallybetween the carousel and the drill head, and clamps at one end of theloading arm configured to secure the one or more consumables. The drillrig further includes a controller coupled to the carousel, the drillhead, and the loading assembly. The controller is configured to receivea full automation mode request; automatically perform a drillingoperation on the working in response to receiving the full automationmode request; automatically perform a resin injection operation on theworking surface subsequent to the drill operation; and automaticallyperform a bolting operation on the working surface subsequent to theresin injection operation.

In some aspects, to automatically perform the bolting operation, thecontroller is further configured to: rotate, using a first actuator, thecarousel to a bolt loading position; secure a bolt from the carousel tothe loading arm; load, using the loading arm, the bolt to the drillhead; align, using the drill head, the bolt with a hole in the workingsurface; rotate, using the first actuator, the carousel to an adapterloading position; secure the adapter from the carousel to the loadingarm; load, using the loading arm, the adapter to the drill head; drive,using the drill head and the adapter, the bolt into the working surface;secure the adapter from the drill head to the loading arm; and unload,using the loading arm, the adapter to the carousel.

In some aspects, the controller is further configured to determinewhether an error has occurred during one of the automatic drillingoperation, the automatic resin injection operation, and the automaticbolting operation; direct a user to manually perform an operation whenthe error has occurred; receive, via a control panel, user inputcorresponding to the operation; and perform the operation based on userinput.

In some aspects, the controller is further configured to determinewhether the error is resolved; generate an alert indicating that thedrill rig is ready for automated operation; receive, via the controlpanel, an input to resume automated operation; and resume one of thedrilling operation, the resin injection operation, and the boltingoperation.

In some aspects, the drill rig further includes a first actuatorconfigured to rotate the carousel about the axis; and an intrinsicallysafe rotary encoder mounted to the carousel and configured to providerotation position signals corresponding to a rotary position of thecarousel. The controller is coupled to the first actuator and theintrinsically safe rotary encoder and the controller is furtherconfigured to control the first actuator to rotate the carousel to oneof the drill loading position, resin cartridge loading position, thebolt loading position, and the adapter loading position based on therotation position signals received from the intrinsically safe rotaryencoder.

Other aspects of the disclosure will become apparent by consideration ofthe detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a drill rig in accordance with anembodiment of the disclosure.

FIG. 2 is another perspective view of the drill rig of FIG. 1 .

FIG. 3 is a top view of the drill rill of FIG. 1 .

FIG. 4 is a perspective view of the drill rig of FIG. 1 , illustrating acarousel.

FIG. 5 is a partial perspective view of the carousel of FIG. 4 .

FIG. 6 is a partial perspective view of the drill rig of FIG. 1 ,illustrating an actuator carried on the carousel.

FIG. 7 is a partial perspective view of the carousel of FIG. 4 ,illustrating a plurality of clips on the carousel.

FIG. 8 is a perspective view of one of the plurality of clips of FIG. 7.

FIG. 9A is a perspective view of the drill rig of FIG. 1 , illustratinga washer loader.

FIG. 9B is another perspective view of the drill rig of FIG. 1 ,illustrating a cam in engagement with a valve actuator.

FIG. 10 is a perspective view of the washer loader of FIG. 9 ,illustrating a portion of an actuator cylinder as transparent.

FIG. 11A is a perspective view of a carrier arm of the washer loader ofFIG. 9 .

FIG. 11B is a partial perspective view of the drill rig of FIG. 1 .

FIG. 12A is a perspective view of an alternate washer loader useablewith the drill rig of FIG. 1 , illustrating the alternate washer loaderin a loading position.

FIG. 12B is a perspective view of the alternate washer loader of FIG.12A, illustrating the alternate washer loader in a lifted position.

FIG. 12C is a perspective view of the alternate washer loader of FIG.12A, illustrating the alternate washer loader in a lifted and retractedposition.

FIG. 12D is a perspective view of the alternate washer loader of FIG.12A, illustrating the alternate washer loader in bit receiving position.

FIG. 13A is a partial perspective view of the drill rig of FIG. 1 ,illustrating a loading arm assembly.

FIG. 13B is a cross-sectional top view of a portion of the loading armassembly of FIG. 13A, taken along the section line 13B-13B of FIG. 13A.

FIG. 14A is a perspective view of a loading arm of the loading armassembly of FIG. 13 .

FIG. 14B is a partially exploded perspective view of an oil coupling andsupport of the loading arm of FIG. 14A.

FIG. 14C is a cross-sectional side view of the support of FIG. 14B.

FIG. 15 is a hydraulic circuit for the drill rig of FIG. 1 .

FIG. 15A is an enlarged view of a portion of the hydraulic circuit ofFIG. 15 .

FIGS. 16A-16O are schematic views of the drill rig of FIG. 1 ,performing a drill cycle.

FIGS. 17A-17H are schematic views of the drill rig of FIG. 1 ,performing a resin cycle.

FIGS. 18A-18M are schematic view of the drill rig of FIG. 1 , performinga bolt cycle.

FIG. 19 is a block diagram illustrating a controller of the drill rig ofFIG. 1 .

FIG. 20 is a perspective view of an intrinsically safe position detectorof the drill rig of FIG. 1 .

FIG. 21 is a perspective view of the intrinsically safe positiondetector of FIG. 20 while coupled to the carousel of FIG. 4 .

FIG. 22 is a plan view of the carousel of FIG. 4 showing a loaded stateof the carousel.

FIG. 23 illustrates an example control panel of the drill rig of FIG. 1.

FIG. 23A illustrates an example button layout of the control panel ofFIG. 23 .

FIG. 24 illustrates an example control panel of the drill rig of FIG. 1.

FIG. 25 illustrates an example user interface during a drill operationof the drill rig of FIG. 1 .

FIGS. 26A and 26B illustrate an example user interface during a resinoperation of the drill rig of FIG. 1 .

FIGS. 27A and 27B illustrate an example user interface during a boltoperation of the drill rig of FIG. 1 .

FIG. 28 is a flowchart of a method for operating the drill rig of FIG. 1in an automatic mode.

FIG. 29 is a flowchart of a method for controlling a drill operation ofthe drill rig of FIG. 1 in an automatic mode.

FIG. 30 is a flowchart of a method for controlling a resin operation ofthe drill rig of FIG. 1 in an automatic mode.

FIG. 31 is a flowchart of a method for controlling a bolt operation ofthe drill rig of FIG. 1 in an automatic mode.

FIG. 32 is a flowchart of a method for controlling an error-handlingoperation of the drill rig of FIG. 1 in an automatic mode.

DETAILED DESCRIPTION

Before any embodiments are explained in detail, it is to be understoodthat the disclosure is not limited in its application to the details ofconstruction and the arrangement of components set forth in thefollowing description or illustrated in the following drawings. Thedisclosure is capable of other embodiments and of being practiced or ofbeing carried out in various ways. Also, it is to be understood that thephraseology and terminology used herein is for the purpose ofdescription and should not be regarded as limiting. Use of “including”and “comprising” and variations thereof as used herein is meant toencompass the items listed thereafter and equivalents thereof as well asadditional items. Use of “consisting of” and variations thereof as usedherein is meant to encompass only the items listed thereafter andequivalents thereof. Unless specified or limited otherwise, the terms“mounted,” “connected,” “supported,” and “coupled” and variationsthereof are used broadly and encompass both direct and indirectmountings, connections, supports, and couplings.

In addition, it should be understood that embodiments may includehardware, software, and electronic components or modules that, forpurposes of discussion, may be illustrated and described as if themajority of the components were implemented solely in hardware. However,one of ordinary skill in the art, and based on a reading of thisdetailed description, would recognize that, in at least one embodiment,aspects may be implemented in software (for example, stored onnon-transitory computer-readable medium) executable by one or moreprocessing units, such as a microprocessor, an application specificintegrated circuits (“ASICs”), or another electronic device. As such, itshould be noted that a plurality of hardware and software based devices,as well as a plurality of different structural components may beutilized to implement the invention. For example, “controllers”described in the specification may include one or more electronicprocessors or processing units, one or more computer-readable mediummodules, one or more input/output interfaces, and various connections(for example, a system bus) connecting the components.

With reference to FIGS. 1-3 , a drill rig 10 (i.e., a drilling rig, abolting rig) is operable to drill or bolt into a work surface (e.g., amine side wall, a mine roof, etc.). The drill rig 10 includes a storageor magazine assembly (e.g., carousel assembly 14) that includes, asillustrated in FIG. 4 , consumables 18 (e.g., drill bits, bolts, resincartridges, adaptors, expendables, self-drilling bolts, combinedbolt-and-resin type bolts, extension drill rods, etc.) carried on arotating magazine or carousel 22. The drill rig 10 also includes aloading assembly 26 with a loading arm 30 that retrieves one of theconsumables 18 from the carousel 22 and loads the consumable 18 into adriver, such as a drill head 34. The drill head 34 and the consumable 18are then fed or driven toward the work surface as the drill head 34translates along a drill axis 36 on a track assembly 38. The drill rig10 includes a controller 40 and is capable of automated operation. Insome embodiments, a complete drill cycle, resin cycle, and bolt cycle,for example, can be performed by the drill rig 10 consecutively withoutmanual interaction with a human operator. As explained in greater detailbelow, the automated drill rig 10 provides improvements in overallefficiency, safety, and compactness.

With reference to FIGS. 3 and 4 , the carousel 22 of the carouselassembly 14 is rotatable about a carousel axis 42. In the illustratedembodiment, the carousel assembly 14 includes a plurality of consumables18 (e.g., drill bits 18A, resin cartridges 18B, bolts 18C, adaptors 18D,expendables, etc.) carried on the carousel 22. The consumables 18 are ofvarious sizes (i.e., different lengths, different diameters) and shapes.In the illustrated embodiment, the carousel assembly 14 includes sixconsumables 18: one drill bit 18A, two resin cartridges 18B, two bolts18C, and an adaptor 18D. In other embodiments, the carousel assembly 14includes any number of consumables or types of consumables. In theillustrated embodiment, the carousel 22 is circular. In otherembodiments, the carousel is non-circular (e.g., oval shaped). Thecarousel 22 is rotatable about the carousel axis 42 to place a desiredconsumable in a position that the loading assembly 26 can retrieve thedesired consumable. In the embodiment illustrated in FIGS. 3 and 4 , thecarousel 22 is shown with the drill bit 18A in a loading position suchthat the loading assembly 26 can access the drill bit 18A and load thedrill bit 18A into the drill head 34. Other consumables can be rotatedinto the loading position as the carousel 22 is rotated.

With reference to FIG. 5 , an actuator 46 (e.g., a hydraulic actuator)is positioned within the carousel 22 and is aligned with carousel axis42. A sensor 50, such as a position sensor, a rotary sensor, or the likeis coupled to the hydraulic actuator 46 and is also aligned with thecarousel axis 42. In the embodiment illustrated in FIG. 5 , the sensor50 is an encoder 50 (e.g., rotary encoder). In the illustratedembodiment, the actuator 46 and the encoder 50 are positioned coaxiallywith the carousel axis 42. Specifically, as illustrated also in FIG. 4 ,the actuator 46 is positioned within a lower mast 54 of the carousel 22,and the encoder 50 is positioned within a casing 58 (shown transparentlyin FIG. 5 ). The encoder 50 may be optical, magnetic, or any other typeof suitable sensor that is configured to detect the rotational positionof the actuator 46 or the carousel 22. The encoder 50 may further beconfigured to detect an axial or translational position of the actuator46 and/or carousel 22. In some embodiments, a plurality of actuators 46may be positioned with the carousel 22. The carousel 22 may be supportedon the casing 58, the actuator 46, and/or lower mast 54 by a bearing orbase rack 60 surrounding the actuator 46.

With reference to FIGS. 6 and 9B, the carousel assembly 14 furtherincludes an arm or cam 62 (FIG. 9B) supported on the carousel 22 forrotation therewith. In some embodiments, the cam 62 is supported on apost or pillar that is coupled to the carousel 22. In the illustratedembodiment, the cam 62 is positioned above (e.g., relative an axiallydirection) the adaptor 18D but may positioned axially below the adapter18D in other embodiments. When the adaptor 18D is in the loadingposition (shown in FIG. 9A), the cam 62 is positioned to engage acorresponding valve actuator 70 (FIG. 9B) that is configured to actuatea hydraulic valve (e.g., a push button solenoid valve, a switch valve,etc.). In the illustrated embodiment, the valve actuator 70 is supportedon a valve manifold 72 (see FIG. 9B). The valve manifold 72 may alsohouse and/or support fluid circuitry and multiple other valves,cylinders, reservoirs, or the like, such as a hydraulic valve.

In response to the valve actuator 70 being actuated (e.g., depressed) bythe cam 62, a valve may alter a fluid flow path of a hydraulic circuit.In the illustrated embodiment, actuating the valve actuator 70 causes ahydraulic circuit that is responsible for raising the loading arm 30 tobe bypassed. In other words, actuating the valve actuator 70 maydeactivate a portion of a hydraulic circuit that is responsible for acertain function (e.g., raising and lowering) of the loading assembly26. For example, engagement of the valve actuator 70 causes the loadingarm 30 not to raise or lower but only rotate. Since the adaptor 18D hasa much shorter length than other consumables, bypassing theraising/lowering actuator of the loading assembly 26 may assist intransferring the adaptor 18D to the feed and/or simplify the path forthe loading arm. In the illustrated embodiments, the cam 62 ispositioned toward an upper portion of the carousel 22. In otherembodiments, the cam 62 and the valve actuator 70 may be positioned at alower or bottom portion of the carousel 22.

With reference to FIG. 7 , a plurality of clip racks 74 are coupled tothe carousel 22 at spaced locations along the carousel axis 42. Each ofthe clip racks 74 is configured to receive a plurality of clips 78positioned about the carousel axis 42 (see FIG. 5 ). In the illustratedembodiment, the clips 78 are received within a recess 82 formed in theclip racks 74. The consumables 18 are removably coupled to the clips 78carried on the carousel 22. In other words, the consumables 18 may beselectively attached or removed from the clips 78 by overcoming abiasing force. The clips 78 elastically deform to facilitate easypush-in and easy pull-out of the consumables 18 from the clips 78. Insome embodiments, the clips 78 could include a grasping member ormoveable lock configured to hold the consumables 18 in the respectiveclip 78.

With further reference to FIG. 7 , the clips 78 are at least partiallyreceived within the recess 82 and secured to the clip rack 74 byfasteners 86. The clips 78 may be easily replaced or swapped out fromthe clip rack 74 according to the desired number and type of consumables18 or as the clip 78 wears out. In the illustrated embodiment, thefasteners 86 are threaded bolts. In other embodiments, another type offastener (e.g., lock bolt, nut, screw, magnet, clamp, etc.) may be used.

With reference to FIG. 8 , the clip 78 includes a base 90 and adeflectable finger 94 that defines an opening 98 in which to receive theconsumable 18. In some embodiments, the base 90 and the finger 94 areformed from an elastically deformable material, such as an elasticallydeformable plastic. The base 90 includes two apertures 102 configured toreceive the fasteners 86 (see FIG. 7 ) that secure the clip 78 to theclip rack 74 when the base 90 of the clip 78 is positioned within therecess 82 (see FIG. 7 ). The clip 78 also includes wear strips 106 thatare positioned adjacent the opening 98. The wear strips 106 provide adurable surface against which the consumable 18 may slide when moving inand out of the opening 98. In the illustrated embodiment, the clip 78includes two wear strips 106 that are molded within the base 90 and thefinger 94 (i.e., insert molded), and the wear strips 106 may be formedof spring steel. The wear strips 106 protect the base 90 and the finger94 from excessive wear during normal operation. In other constructions,one or more wear strips 106 are omitted and the clip 78 itself is formedof or with a similar durable surface to that of the wear strips 106. Insome embodiments, the wear strips 106 may provide additional elasticgripping force.

During operation of the carousel assembly 14, the actuator 46 can beactivated by the controller 40 based on feedback from the encoder 50 torotate the carousel 22 about the carousel axis 42. The carousel 22 ispositioned in a desired orientation (e.g., an indexed position) to placethe desired consumable 18 in the loading position, in which the desiredconsumable can be retrieved by the loading assembly 26. As illustratedin FIG. 9B, when the carousel 22 is positioned with the adaptor 18D inthe loading position, the cam 62 engages the valve actuator 70 todeactivate a portion of hydraulic circuit of the loading assembly 26.The consumables 18 are selectively coupled to the carousel 22 by theclips 78 and are released from the carousel 22 when the loading assembly26 overcomes the threshold force required to deflect the finger 94,thereby releasing the consumable 18 from the carousel 22. Further detailof the carousel assembly 14 operation is described below in reference tothe overall operation of the drill rig 10.

With specific reference to FIGS. 1 and 9A-11B, the drill rig 10 includesa washer loader assembly 110 configured to load a washer 114 onto aconsumable 18 (e.g., a drill bit 18A). The washer loader assembly 110includes a plurality of washers 122 (see FIG. 10 ) stored at an axialend 118 (e.g., an upper end) of the carousel assembly 14, forming astack of washers 122. The stack of washers 122 is aligned (i.e.,coaxial) with the carousel axis 42. In the illustrated embodiment, thestack of washers 122 is positioned on a plate 126 positioned adjacent anupper end of the carousel 22.

As illustrated in FIGS. 1-3 and 9A-11B, the washer loader assembly 110also includes a carrier arm 130 that is configured to move a singlewasher 114 from the stack of washers 122 and position the washer 114co-axially with the consumable 18 that is coupled to the loadingassembly 26, as explained in greater detail below.

With specific reference to FIG. 10 , the carrier arm 130 is coupled at afirst end 134 to an actuator 138. The actuator 138, along with thecarrier arm 130, is configured to extend and rotate with respect to afixed casing 142 (see also FIG. 9A). Specifically, the actuator 138defines an axis 146 along which the actuator 138 extends and about whichthe actuator 138 rotates. In the illustrated embodiment, a support postor sleeve 150 is positioned between the casing 142 and the actuator 138.The sleeve 150 includes a groove 154 that captures a corresponding pin158 formed on the actuator 138. As the actuator 138 is extended from thecasing 142, the pin 158 moves within the groove 154.

In the illustrated embodiment, the sleeve 150 may is a two-piece sleevethat includes a first sleeve (e.g., an upper sleeve) 150A and a secondsleeve (e.g., a lower sleeve) 150B with the groove 154 extending in theupper and lower sleeves 150A, 150B. The groove 154 includes a flair 156that allows for minor relative rotation between the sleeves 150A, 150B.The flair 156 may have a generally diamond shape and be disposed at ajunction 157 between the first sleeve 150A and the second sleeve 150B.In the illustrated embodiment, the sleeves 150A, 150B are allowed torotate by approximately (+/−) 5-degrees relative one another. Providingminimal relative rotation between the sleeves 150A, 150B allows forseparate positional adjustments of the first sleeve 150A and the secondsleeve 150B. Hydraulics may be applied to the sleeve 150 to improvecontrol during movement of the actuator 138 and the arm 130.

With continued reference to FIG. 10 , the groove 154 includes a linearportion 162 and a curved portion 166 position on either side of theflair 156. As the pin 158 moves along the linear portion 162 of thegroove 154, the actuator 138 extends away from the casing 142,translating along the axis 146. As the pin 158 moves along the curvedportion 166 of the groove 154, the actuator 138 extends away from thecasing 142 along the axis 146 and rotates relative to the casing 142about the axis 146. The flair 156 allows the pin 158 to slightly deviatefrom the linear portion 162 and the curved portion as it passes betweenthe sleeves 150A, 150B. In other words, the actuator 138 extends androtates simultaneously as the pin 158 moves past the flair 156 andthrough the curved portion 166 of the groove 154 in the sleeve 150. As aresult, the carrier arm 130 is raised away from and rotated relative tothe stack of washers 122 upon activation of the actuator 138. In theillustrated embodiment, a position of the groove 154 above the flair 156can be adjusted relative a position of the groove 154 below the flair156 to thereby adjust a starting or ending position of the carrier arm130.

With reference to FIGS. 10 and 11 , the carrier arm 130 includes aforked portion 170 positioned at a second end 174, opposite the firstend 134. The forked portion 170 defines an opening 178 through which oneof the consumables 18 may pass, as explained in greater detail below.The carrier arm 130 also includes one or more magnets 182 (i.e., amagnetic coupling) positioned adjacent a surface 186 that faces thestack of washers 122. In the illustrated embodiment, the magnets 182 arepermanent magnets positioned within one or more recessed portions 183 onthe arm 130. In other embodiments, the magnets 182 are permanent magnetspositioned adjacent to the opening 178.

During operation of the washer loader assembly 110, the magnet 182 onthe carrier arm 130 is capable of magnetically coupling one of thewashers from the stack 122 to the carrier arm 130. The carrier arm 130is then raised and rotated by the actuator 138 to reposition the singlewasher 114 from a stored position on the stack of washers 122 to amounting position. In the mounting position, the washer 114 is alignedwith a consumable 18 carried by the loading assembly 26 and isconfigured to receive the consumable 18 controlled by the loadingassembly 26 (e.g., FIG. 16D-16F). In other words, with the washer 114 inthe mounting position (FIG. 16D), the consumable 18 is translated by theloading assembly 26 through a central aperture in the washer 114 (FIG.16E). The loading assembly 26 then moves the consumable 18 and thewasher 114 away from the carrier arm 130, thereby breaking the magneticcoupling between the carrier arm 130 and the washer 114 (FIG. 16D-16F).As the consumable 18 and the washer 114 move away from the carrier arm130, the consumable 18 moves through the opening 178 formed in thecarrier arm 130.

With reference to FIGS. 2, 9A, and 11B, a balance rod 190 is coupled tothe loading assembly 26 and is configured to support the washer 114 oncethe washer 114 has been loaded onto the drill bit 18A. As described ingreater detail below, the balance rod 190 supports the washer 114 inposition on the drill bit 18A as the loading assembly 26 moves the drillbit 18A and until the drill bit 18A has been coupled to the drill head34. Once the drill bit 18A has been coupled to the drill head 34, thewasher 114 is received within a recess 194 formed in a top plate 198 ofthe drill rig 10. The top plate 198 includes an opening or bore 200through which the consumable may be driven. The drill axis 36 is alignedwith the bore 200. In the illustrated embodiment, the recess 194 iscircular shaped and is aligned with the drill axis 36. The top plate 198and the recess 194 include a section 202 that has been removed (i.e., acut-out) in order to allow the consumable 18 to translate in and out ofthe bore of the top plate 198.

As such, the washer 114 is automatically loaded onto the drill bit 18Aduring a drill cycle (FIG. 16A-16O) of the drill rig 10. The drill rig10 therefore automates the addition of the washer 114 to the consumable18A, which would otherwise be loaded manually onto the consumable. Thedrill rig 10 also maintains the ability to override or temporarily haltoperation of the washer loader 110 to selectively allow an operator theability to load and/or unload a washer 114 on/from the consumable 18A.

As explained in more detail below, the washer loader assembly 110automatically loads a washer 114 onto a desired consumable 18A, but notonto other consumables 18B, 18C, 18D that do not require a washer. Thewasher 114 is supported on the consumable 18A by the balance rod 190until the consumable 18A is loaded in the drill head 34 and the washer114 is received within the recess 194 formed in the top plate 198.

With reference to FIGS. 12A-12D, an alternate washer loader assembly 110a usable with the drill rig 10 obviates the need for the balance rod 190coupled to the loading assembly 26. Rather than the balance rod 190positioned on the loading assembly 26 to temporarily support the washer114, the washer 114 is centered on the consumable 18A before theconsumable 18A is centered in the drill head 34. Other than the balancerod 190 being obviated, the alternate washer loader assembly 110 aoperates in a similar or common manner as the washer loader assembly100, as described below.

FIG. 12A illustrates the alternate washer loader assembly 110 a in aloading position, in which a loading arm 130 a of the alternate washerloader assembly 110 a is extended along a washer loader axis 112.

FIG. 12B illustrates the alternate washer loader assembly 110 a in alifted position, in which the loading arm 130 a of the alternate washerloader assembly 110 a is extended along the washer loader axis 112 andlifted along a washer loader axis 146 a. The loading arm 130 a is liftedabove an upper end of the consumable 18A supported on the carousel 22.

FIG. 12C illustrates the alternate washer loader assembly 110 a in alifted and retracted position, in which the loading arm 130 a of thealternate washer loader assembly 110 a is retracted along a washerloader axis 112 relative the extended position. The loading arm 130 aremains lifted above an upper end of the consumable 18A such that, asthe loading arm 130 a is retracted, a center of the washer 114 passesover a center of the consumable 18A. The consumable 18A is offsetrelative the washer 114 such that retracting the loading arm 130 acenters the washer 114 over the consumable 18A.

FIG. 12D illustrates the alternate washer loader assembly 110 a in a bitreceiving position, in which the loading arm 130 a of the alternatewasher loader assembly 110 a is retracted along the washer loader axis112 and lifted along the axis 146 a. FIG. 12D further illustrates theconsumable 18A lifted into the washer 114. The alternate washer loaderassembly 110 a further includes a guide protrusion 113 that extends fromthe alternate washer loader assembly 110 a adjacent the loading arm 130a.

As shown in FIGS. 12A-12D, the guide protrusion 113 is partially curvedto generally correspond to the curved movement of the loading assembly26. The guide protrusion 113 is positioned on the alternate washerloader assembly 110 a such that the washer 114 is guided into the drillhead 34 as the loading assembly 26 rotates the consumable 18A and washer114 out of/away from the loading arm 130 a. In other words, the guide113 extends far enough away from the loading arm 130 a such that thewasher 114 does not fall down the consumable 18A past the drill head 34.

With reference to FIGS. 13A, 13B, and 14A, the loading assembly 26 isillustrated with the loading arm 30 positioned adjacent the carouselassembly 14. Specifically, the loading arm 30 can be positioned adjacentto the consumables 18 (e.g., adaptor 18D) carried on the carousel 22while in the loading position. The loading assembly 26 includes a firstactuator 206 configured to raise and lower the loading arm 30 and asecond, separate actuator 210 configured to rotate the loading arm 30.The first actuator 206 defines a first axis 214 and the second actuator210 defines a second axis 218. In the illustrated embodiment, the firstaxis 214 is spaced apart and oriented parallel to the second axis 218.The first actuator 206 and the second actuator 210 allows for theloading arm 30 to be raised and lowered independently of rotation. Inother words, the loading arm 30 can be raised or lowered (i.e.,translated along the first axis 214) without being rotated (i.e.,rotated about the second axis 218). Likewise, the loading arm 30 can berotated about the second axis 218 without being raised or lowered alongthe first axis 214. Independent control of the loading arm 30 movementoffers greater flexibility in controlling the loading assembly 26 toperform various tasks.

With continued reference to FIG. 13A, the loading arm 30 has a fixedlength. The loading arm 30 does not need to be extended in order to movethe consumables 18 from the carousel 22 or to load the consumable 18into the drill head 34. In other words, a separate actuator is notrequired to translate the loading arm in a direction transverse to thesecond axis 218. Stated another way, the distance between the drill head34 and the second axis 218 is equivalent to the distance between theconsumables 18 in the loading position on the carousel 22 and the secondaxis 218. As such, a distance between the drill head 34 and the secondaxis 218 is equal to the distance between the second axis 218 and thecarousel assembly 14.

With reference to FIGS. 13B and 14A, the loading arm 30 includes twoclamp plates 222 that are configured to move between an open position(FIGS. 13B and 14A) and a closed position, where the clamp plates 222are positioned around and secured to the consumable 18. In theillustrated embodiment, each clamp plate 222 includes a groove 226 inwhich to receive the consumable 18 when in the closed position. Themovement of the clamp plates 222 and the shape of the grooves 226 in theclamp plates 222 are configured to capture consumables having a varietyof diameters. The loading arm 30 also includes a sensor 230 (see FIG.14A) positioned adjacent the clamp plates 222. As shown in FIG. 13B, aclamp actuator 225 may be operated to move the clamp plates 222, asdetailed below. In some embodiments, the actuator 210 may be operated tomove the clamp plates 222.

Referring to FIG. 13B, the clamp actuator 225 is operable to drive apiston that is positioned in an actuator housing 225 b. A rod of thepiston 225 a is secured to a coupling plate 225 d (e.g., by a bolthaving a head 225 c). The coupling plate 225 d is coupled to the clampplates 222 by a linkage 225 e by, for example, one or more couplers 225f. The linkage or bar arrangement of the plate 225 d, linkage 225 e, andclamp plate 222 translates linear or axial movement of a part of theactuator 225 (e.g., the piston 225 a) into rotational movement of theclamp plates 222. In the illustrated embodiment, the plate 225 d iscoupled to both clamp plates 222. In some embodiments, more than onelinkage 225 e may be coupled between the plate 225 d and the clamp plate222.

In some embodiments, as shown in FIG. 14B, pressurized fluid may beprovided to an actuator on loading arm (e.g., the actuator for movingclamp plates 222) by a fluid coupling 232. The loading arm 30 issupported for rotation relative to the fluid coupling 232 such thatlubricant supply hoses do need to rotate with the loading arm 30.Rather, the fluid coupling 232 supports a lubricated bearing or coneshape that accommodates delivery of fluid to a rotational part of theclamp plates 222 and loading arm 30. The fluid coupling 232 includes aplurality of cavities 232 a, such as tunnels, galleries, or the like.The cavities 232 a are positioned around a circumference of the fluidcoupling 232 to supply fluid to the loading arm 30. In the illustratedembodiment, the cavities 232 a extend radially outwardly and arepositioned around approximately half of an outer circumference of thefluid coupling 232. In other embodiment, the cavities 232 a arepositioned around more than half (e.g., 75%, 100%, etc.) of the outercircumference of the fluid coupling 232. In some embodiments, thecavities 232 a are capped or plugged at one end and pressurized toprovide pressurized fluid to loading arm 30 and clamp actuator 225. Theloading arm 30 includes a plurality of complementary receptaclesconfigured to receive fluid from the cavities 232 a. In other words, thecavities 232 a on the fluid coupling 232 provide a first port and thecomplementary receptacles on the loading arm 30 provides a second portto maintain fluid communication with the first port throughout therotational motion of the loading arm 30. A lubricant may be provided tocomponents on the loading arm 30 in a similar manner.

As illustrated in FIGS. 14B and 14C, a portion of the loading arm 30 maybe supported by a key arrangement 233 that accommodates sliding movement(e.g., along the axis 218) of the loading arm 30. The key arrangement233 includes a support mast or axially fixed shaft 233 a, two keys 233 breceivable in a portion of the support mast 233 a, and an inner shaft233 c that is received in the support mast 233 a and axially moveable(e.g., slidable) relative, for example, the oil coupling 232. The keys233 b are retained to the support mast 233 a by a carrier 233 d, suchas, for example, a split band wear carrier 233 d. The carrier 233 d is atwo-piece carrier that supports one or more wear bands 233 e. The keys233 b are sized and shaped to contact a grooved surface on the innershaft 233 c to prevent relative rotation between the support mast 233 aand the inner shaft 233 c. The keys 233 b thus support axial movement ofthe loading arm 30 and prevent wear or damage between the shaft 233 a,233 c during movement.

The loading arm 30 is further supported for rotation on an outer shaft233 g that slides with the inner shaft 233 c. In the illustratedembodiment, the inner and outer shafts 233 c, 233 g do not move axiallyrelative one another, and both shafts 233 c, 233 g move axially relativethe support mast 233 a. The outer shaft 233 g particularly supportrotation of the loading arm 30 through the wear bands 233 e thatsurround the wear band carrier 233 d. The wear bands 233 e contact theouter shaft 233 g and accommodate protected relative rotation betweenthe keys 233 b and the loading arm 30 on the outer shaft 233 g. In otherwords, the wear bands 233 e assist in preventing wear (e.g., betweenabrasive or touching surfaces) in the loading assembly 26 as the loadingarm 30 is rotated or translated. During installation of the keyarrangement 233, the keys 233 b are inserted into the support mast 233a, and the portions of the carrier 233 d are positioned around the keys233 b. The wear bands 233 e are pressed or forced over the carrier 233 dto hold the bands 233 e, the carrier 233 d, and the keys 233 b to thesupport mast 233 a.

In the illustrated embodiment, the wear bands 233 e are made of apolymer, such as polyester. The wear band carrier 233 d is made ofmetal, such as cast iron, steel, stainless steel, or the like. In otherembodiments, the wear band carrier 233 d is made of a rigid polymer. Inthe illustrated embodiment, the carrier 233 d is made of steel. The keys233 b are also made of a metal, such as brass, copper, aluminum, or thelike. In the illustrated embodiment, the keys 233 b are brass.

In the illustrated embodiment, the sensor 230 is a proximity sensor thatdetects when the consumable 18 is gripped by the loading arm 30 (i.e.,positioned between the clamp plates 222). In some embodiments, thesensor 230 is an inductive sensor detecting a presence of a metallicmaterial. The two clamp plates 222 are moved between the open positionand the closed position using the clamp actuator 225 (see FIG. 14A), forexample, a hydraulic actuator, a motor, a solenoid, or the like. Theclamp actuator 225 is part of the drive motors and actuators 332controlled by the controller 40, as described in detail below.

With reference to FIG. 15 , the drill rig 10 includes a hydrauliccircuit 234 to power various functionality on the drill rig 10. Thehydraulic circuit 234 includes a main pressure source 238 and a mainreturn 242. The hydraulic circuit 234 also includes a function-selecthydraulic line 246 and a hydraulic return 250 (i.e., a second hydraulicreturn). The hydraulic circuit 234 also includes main flow valves 254and diversion valves 258 that are fluidly coupled to a hydraulicfunction 262 on the drill rig 10. In some embodiments, the hydraulicfunction 262 includes index tilt left/right; carousel rotate; index tiltfore/aft; rotate loading arm; raise/lower loading arm; open/close jaws;washer loader; auxiliary functions, or any other suitable hydraulicfunction on the rig 10. The hydraulic functions 262 can include varioushydraulic components, for example: actuators; cylinders; hydraulicmotors; pressure compensation valves; and check valves.

With continued reference to FIG. 15 , the hydraulic functions 262 arepaired together to create a hydraulic sub-circuit 266 that includes aprimary hydraulic function 270 and a secondary hydraulic function 274.The main pressure source 238 and the main return 242 fluidly communicatewith each of the hydraulic sub-circuits 266 in parallel. The secondhydraulic return 250 is fluidly coupled to each of the diversion valves258. Likewise, the function-select hydraulic line 246 is fluidly coupledto each of the diversion valves 258. In the illustrated embodiment, themain flow valves 254 are three-position, solenoid-actuated,electronically controlled hydraulic valves. In the illustratedembodiment, the diversion valves 258 are two-position, hydraulic valveswith a spring-biased neutral position.

With reference to FIG. 15A, each hydraulic sub-circuit 266 includes afirst diversion valve 258A, a second diversion valve 258B, and a mainflow valve 254. An input side 278 of the main flow valve 254 isconnected to the main pressure source 238 and the main return 242. Themain flow valve 254 has a closed neutral position and is electronicallycontrolled by a solenoid between two open positions to providedirectional control of the hydraulic function 262. For example, the mainflow valve 254 is controlled to move to a first open position to rotatethe carousel 22 in a first direction about the carousel axis 42 (e.g.,clockwise) and the main flow valve 254 is controlled to move to a secondopen position to rotate the carousel 22 in a second direction, oppositethe first direction (e.g., counter-clockwise). An output side 282 of themain flow valve 254 are in fluid communication with an inlet side 286 ofboth the first diversion valve 258A and the second diversion valve 258B.The second hydraulic return 250 is also fluidly communicating with theinlet side 286 of the first diversion valve 258A and the seconddiversion valve 258B. An output side 290 of each of the diversion valves258 is fluidly coupled to both the primary hydraulic function 270 andthe secondary hydraulic function 274.

With continued reference to FIG. 15A, the diversion valves 258 have afirst, spring-biased open position and a second open position. Theposition of the diversion valve 258 is determined by the pressure in thefunction-select hydraulic line 246. For example, when the pressure inthe function-select hydraulic line 246 is low or near atmosphere, thefirst diversion valve 258A and the second diversion valve 258B arespring-biased into the first open position, as illustrated in FIG. 15A,thereby activating the primary hydraulic function 270 and deactivatingthe secondary hydraulic function 274. On the other hand, when thepressure in the function-select hydraulic line 246 is higher, the firstdiversion valve 258A and the second diversion valve 258B are forced intothe second open position (against the spring bias), thereby activatingthe secondary hydraulic function 274 and deactivating the primaryhydraulic function 270. In other words, the pressure in thefunction-select hydraulic line 246 is toggled high and low to determinewhether the primary function 270 or the secondary function 274 isactivated by being placed in fluid communication with the main pressuresource 238 and the main return 242. The deactivated hydraulic functionis placed in fluid communication with the second hydraulic return 250 torelease any stored pressure. In some embodiments, the two diversionvalves 258A and 258B are combined into a single six-way, two-positiondirection control valve (e.g., the Model: KVH-6/2-8 directional valveavailable from Porclain Hydraulics or the Model: DNDY valve availablefrom Sun Hydraulics).

The diversion valves 258 are small and therefore reduce the overall sizeof the drill rig 10. In other words, the diversion valves 258 aresmaller than an additional solenoid operated directional control valve,which also requires an additional solenoid and electrical components. Inaddition, the diversion valves 258 are hydraulically actuated by thefunction-select hydraulic line 246 and are not electronicallycontrolled, thereby reducing the complexity of the electronics. In otherwords, the diversion valves 258 replace electronically controlledsolenoid valves. A single solenoid-actuated flow valve 254 can fluidlycommunicate the main pressure source 238 and the main return 242 to twodifferent hydraulic functions (i.e., the primary function 270 and thesecondary function 274). In this sense, the hydraulic circuit 234provides a dual-functionality for each of the flow valves 254.

With reference to FIGS. 16A-16O, FIGS. 17A-17H, and FIGS. 18A-18M acomplete, automated operation cycle of the drill rig 10 is illustrated.In the illustrated embodiment a complete, automated operation cycleincludes a drill cycle (FIGS. 16A-16O), a resin cycle (FIGS. 17A-17H),and a bolt cycle (FIGS. 18A-18M). The drill rig 10 automaticallyperforms the drill cycle, followed by the resin cycle, followed by thebolt cycle. In other embodiments, the drill rig 10 may perform anynumber of desired cycles and in any desired sequence, and/or only someof the cycles may be performed. In the illustrated embodiment, a workingsurface 294 is a roof of an underground mine. As explained above, theworking surface may also be a wall of an underground mine, for example,and the drill rig 10 can be oriented accordingly. In other words, thedrill rig 10 is operable while positioned in more than one orientation(e.g., both an up-down vertical orientation and a left-right horizontalorientation)

With reference to FIGS. 16A-16O, the drill cycle of the drill rig 10 isillustrated. FIG. 16A illustrated the drill rig 10 in a startingposition relative to the working surface 294. In the starting position,the drill head 34 is positioned to receive the consumable 18, and thetop plate 198 is retracted.

FIG. 16B illustrates the consumables 18 and the washers 114 (e.g., stackof washers 122) being loaded into the carousel assembly 14 and drill rig10.

FIG. 16C shows the drill rig 10 moving to a start position after beingloaded with the consumables 18 and the washer 114. The actuator 138 ofthe washer loader assembly 110 retracts and rotates such that thecarrier arm 130 magnetically engages with a washer 114. The carouselassembly 14 is rotated to position the desired consumable (i.e., thedrill bit 18A) into the loading position such that it can be loaded intothe loading arm 30.

FIG. 16D illustrates the washer loader assembly 110 with the actuator138 and the carrier arm 130 extended and rotated. The carrier arm 130holds the washer 114 in a position that is aligned with the drill bit18A, which is now secured to the loading arm 30.

FIG. 16E illustrates that the loading arm 30 and the drill bit 18A areextended along the axis 214 (i.e., raised) such that the drill bit 18Apasses through the center aperture of the washer 114.

FIG. 16F illustrates the loading arm 30 and the drill bit 18A with thewasher 114 rotated about the second axis 218 such that the drill bit 18Ais aligned with the drill head 34.

FIG. 16G illustrates the drill head 34 translated along the drill axis36 in order to receive the drill bit 18A within the drill head 34 (i.e.,within a chuck). During the steps shown in FIGS. 16F-16G, the balancerod 190 contacts the washer 114 and maintains the washer 114 in positionwith respect to the drill bit 18A.

FIGS. 16H-16J illustrate the drill bit 18A, the drill head 34, and thetop plate 198 translating along the drill axis 36 such that the drillbit 18A drills a hole into the working surface 294 and the top plate 198with the washer 114 abuts the working surface 294.

FIGS. 16K-16O illustrate the end of the drill cycle where the drill bit18A and drill head 34 are retracted away from the working surface 294and the drill bit 18A is returned to the carousel 22 by the loading arm30. In the illustrated embodiment, the top plate 198 and the washer 114remain abutted against the working surface 294 at the end of the drillcycle (FIG. 16O).

FIGS. 17A-17H illustrate the resin cycle of the drill rig 10. The resincycle is similar to the drill cycle but with a resin cartridge 18Binstead of a drill bit 18A being selected from the carousel assembly 14by the loading arm 30. In other words, the loading arm 30 moves theresin cartridge 18B from the carousel assembly 14 to the drill head 34(FIGS. 17A-17D); the resin cartridge 18B is inserted into the workingsurface 294 (FIGS. 17E-17F); and the resin cartridge 18B is returned tothe carousel assembly 14 by the loading arm 30 (FIGS. 17G-17H). Beforethe resin cartridge 18B is returned to the carousel assembly 14, resinis ejected from the resin cartridge 18B and into the hole drilled by thedrill bit 18A. The resin may be ejected from the resin cartridge 18B bya resin inserter or ejector. In the illustrated embodiment, a fluid suchas water, oil, a water-oil mixture, or the like is pressurized in theinserter to eject or press the resin from the resin cartridge 18B.

FIGS. 18A-18M illustrate the bolt cycle of the drill rig 10. The boltcycle is similar to the drill cycle but with a bolt 18C (and optionally,the adaptor 18D) instead of a drill bit 18A being selected from thecarousel assembly 14 by the loading arm 30. First, the bolt 18C isloaded into the drill head 34 and partially inserted into the workingsurface 294 (FIG. 18A-18E). Next, the drill head 34 is retracted withthe bolt 18C remaining in position (FIG. 18F). In the illustratedembodiment, the bolt 18C is held in place by the top plate 198. In someembodiments, the top plate 198 includes a clamp that holds the bolt 18Cin position. The loading arm 30 then moves the adaptor 18D from thecarousel 22 to the drill head 34 (FIGS. 18G-181 ).

The loading arm 30 does not raise or lower when loading the adaptor 18Dbecause the cam 62 and valve actuator 70 disengage the first actuator206. Instead, the drill head 34 is moved to accommodate loading theadaptor 18D into the drill head 34 and the adaptor 18D is held inposition. Then, the adaptor 18D is used to complete the insertion of thebolt 18C into the working surface 294 (FIGS. 18J-18K), and the adaptor18D is returned to the carousel 22 (FIGS. 18L-18M). In some embodiments,the bolt 18C may be loaded and driven by the drill head 34 without useof the adaptor 18D.

The drill rig system 300 and the controller 40 are illustrated ingreater detail with respect to FIG. 19 . The controller 40 iselectrically and/or communicatively connected to a variety of modules orcomponents of the drill rig system 300. For example, the controller 40may be connected to a user interface 304, a consolidated controller 306,a network switch 308 (via consolidated controller 306), a centralcontroller 312 (via network switch 308), a network 316 (via networkswitch 308), a power supply module 320 (e.g., an AC power supply modulereceiving AC mains power), one or more sensors 324 related to the drillrig system 300, a database 328 (e.g., for storing data, images, and/orvideo related to the drill rig system 300, component profiles, etc.),and/or one or more drive motors and actuators 332 of the drill rigsystem 300.

The one or more drive motors and actuators 332 include one or more ofthe motors and actuators of the drill rig 10. For example, the one ormore drive motors and actuators 332 include the actuator 46 (i.e., afirst actuator) configured to rotate the carousel 22, the actuator 138(i.e., a second actuator) configured to extend and rotate the carrierarm 130 with respect to the fixed casing 142, the actuator 206 (i.e., athird actuator) configured to raise and lower the loading arm 30, theactuator 210 (i.e., a fourth actuator) configured to rotate the loadingarm 30, and the clamp actuator 225 (i.e., a fifth actuator) to open andclose the clamps 222. The sensors 324 may include one or more sensors ofthe drill rig 10. For example, the sensors 324 may include the encoder50 configured to detect the rotational position of the carousel 22 andthe sensor 230 to detect a consumable proximate the loading arm 30. Inaddition to the encoder 50 and the sensor 230, the sensors 324 mayinclude a feed pressure sensor, a fine feed speed sensor, a rotationpressure sensor, a rotation speed sensor, an inclinometer, and/or a flowsensor.

The controller 40 includes combinations of hardware and software thatare operable to, among other things, control the operation of the drillrig 10, communicate with a central controller 312 or over the network316, among other functions. In some embodiments, the controller 40includes a plurality of electrical and electronic components thatprovide power, operational control, and protection to the components andmodules within the controller 40 and/or drill rig 10. For example, thecontroller 40 includes, among other things, a processing unit 336 (e.g.,a microprocessor, a microcontroller, or another suitable programmabledevice), a memory 340, input units 344, and output units 348. Theprocessing unit 336 includes, among other things, a control unit 352, anarithmetic logic unit (“ALU”) 356, and a plurality of registers 360(shown as a group of registers in FIG. 19 ), and is implemented using aknown computer architecture (e.g., a modified Harvard architecture, avon Neumann architecture, etc.). The processing unit 336, the memory340, the input units 344, and the output units 348, as well as thevarious modules connected to the controller 40 are connected by one ormore control and/or data buses (e.g., common bus 364). The controland/or data buses are shown generally in FIG. 19 for illustrativepurposes.

The memory 340 is a non-transitory computer readable medium andincludes, for example, a program storage area and a data storage area.The program storage area and the data storage area can includecombinations of different types of memory, such as a ROM, a RAM (e.g.,DRAM, SDRAM, etc.), EEPROM, flash memory, a hard disk, an SD card, orother suitable magnetic, optical, physical, or electronic memorydevices. The processing unit 336 is connected to the memory 340 andexecutes software instructions that are capable of being stored in a RAMof the memory 340 (e.g., during execution), a ROM of the memory 340(e.g., on a generally permanent basis), or another non-transitorycomputer readable medium such as another memory or a disc. Softwareincluded in the implementation of the drill rig 10 can be stored in thememory 340 of the controller 40. The software includes, for example,firmware, one or more applications, program data, filters, rules, one ormore program modules, image processing software, and other executableinstructions. The controller 40 is configured to retrieve from thememory 340 and execute, among other things, instructions related to thecontrol processes and methods described herein. In other constructions,the controller 40 includes additional, fewer, or different components.In some embodiments, the software included in the implementation of thedrill rig 10 can be stored in a memory of the central controller 312. Insuch embodiments, the central controller 312 is configured to retrievefrom the memory and execute instructions related to the controlprocesses and methods described herein.

In mining environments, electrically components are desired to beintrinsically safe. For a device to be certified as intrinsically safe,every electrical element of the device is to perform according to theintrinsically safe standard specified. Rotary encoders present aroadblock for such certification. Multi-turn and optical encoders, whichare typically used in mining equipment, are too large to and difficultto configure to be intrinsically safe. One alternative solution tomulti-turn and optical encoders is to use mechanical encoders that donot use electrical components. However, mechanical encoders are notgenerally reliable, experience wear and tear, and are faced withcoupling alignment and fitment issues.

FIG. 20 illustrates an intrinsically safe rotary encoder 50 configuredto detect the rotational position of the carousel 22. In the exampleillustrated, the intrinsically safe rotary encoder 50 is a magneticposition sensor including one or more Hall-effect sensors that detect apermanent magnet attached to the carousel 22. As shown in FIG. 20 , theencoder 50 includes a position sensor 384 (e.g., Hall sensor) on a topportion of a housing 392. The housing 392 is formed from a protectivematerial configured to house the position sensor 384. In someembodiments, the housing 392 is a stainless steel or other metal housingconfigured to arrest any flames or cut-off oxygen supply to any flamegenerated within the housing. Magnetic rotary encoders provide asignificant temperature advantage over multi-turn and optical encoders.Hall sensor outputs operate at a power level of below 1 Watt (W) withminimal heat loss. Such low levels of power generate minimal heat makingit easier to meet the intrinsically safe limitations. Although magneticrotary encoders provide a significant advantage over other types ofencoders, magnetic rotary encoders are currently not extensively used inthe mining industry. The magnetic rotary encoder provides a contactlessposition detection mechanism. Magnetic encoders need to be positionedvery close to a sensed element to provide accurate measurements.Additionally, the output signals provided by generally available Hallsensors are not compatible with the communication and sensing techniquesused by a control system of a mining machine.

To overcome the above challenges, the position sensor 384 is exposedfrom the housing 392 such that the position sensor 384 can be placed inclose contact with a magnet of the carousel. Specifically, the positionsensor 384 is provided outside a periphery of the housing 392. Withreference to FIG. 21 , the intrinsically safe rotary encoder 50 isprovided at a bottom of the carousel 22. In some embodiments, the rotaryencoder 50 may be provided at a top of the carousel 22. The housing 392of the rotary encoder 50 is fixed to a housing of the carousel 22 usingfasteners. A gasket or seal may be provided between the rotary encoder50 and the carousel 22 to provide an air-tight and/or water-tight sealbetween the rotary encoder 50 and the carousel 22. As discussed above,the position sensor 384 is exposed from the housing 392 such that theposition sensor 384 extends into a housing of the carousel 22. Therotary encoder 50 is fixed to the carousel such that the position sensor384 is in close proximity to a magnet fixed to a rotary shaft of thecarousel 22. The magnet includes at least two poles (one North and oneSouth), which are detected by the position sensor 384. The detectionsignals are then forwarded to the controller 40 to indicate a rotaryposition of the carousel 22. In some embodiments, the magnet may includeadditional poles (e.g., two or more North and two or more South) toprovide additional granularity in rotation position measurement. In someembodiments, the position sensor 384 may be provided within theperiphery of the housing 392 and the magnet of the carousel can beextended into the housing 392 of the rotary encoder 50 to place themagnet in close proximity to the position sensor 384.

Depending on the type of magnetic encoder used, the rotary encoder 50may provide an analog output, a pulse-width modulated (PWM) output, aserial peripheral interface output, and the like. Accordingly, an analogto digital converter (ADC) or a Universal AsynchronousReceiver-Transmitter (UART) to convert the output signal from one form(e.g., analog) to another form (UART) such that the rotary encoder 50may be integrated with other components of the drill rig 10.

FIG. 22 illustrates an exemplary configuration of the carousel 22. Thecarousel 22 includes one or more stations 400 for loading one or moreconsumables 18. For example, as illustrated in FIG. 22 , a first station400A is loaded with a drill bit 18A. A second station 400B and a thirdstation 400C are each loaded with a resin cartridge 18B. A fourthstation 400D and a fifth station 400E are each loaded with a bolt 18C. Asixth station 400F is loaded with an adaptor 18D. The currently selectedstation 400 of the carousel 22 may be determined by the intrinsicallysafe position detector 50. An angular position of the carousel 22 may beidentified by the rotary encoder 50) based on a magnet, a target, orsome other object mounted to the carousel 22. For example, asillustrated in FIG. 22 , the carousel is positioned at 0°.

The drill rig 10 further includes an intrinsically safe control panel420. The control panel 420 is part of the user interface 304 and isconnected to the controller 40. FIGS. 23 and 24 illustrates a firstexample embodiment of a control panel 420A and a second exampleembodiment of a control panel 420B for controlling the drill rig 10. Thefirst control panel 420A and the second control panel 420B include adisplay screen 424, a speaker 428, and one or more buttons (e.g., aplurality of buttons). The one or more buttons are provided as a keypad430. The keypad 430 has a thickness between 0.15 millimeter (mm) and 1mm. The one or more buttons include a combination of single press on/offbuttons that toggle states when pressed and proportional input buttonsthat provide a signal to the controller proportional to the forceapplied on the button. When the one or more buttons includes aproportional input button, a force sensing resistor material is providedbelow the plastic overlay for each proportional input button. The forceapplied on the one or more buttons is transmitted to the force-sensingresistor material, which causes a drop in the electrical resistance ofthe force-sensing resistor. This drop in electrical resistance isdetected to determine the amount of force applied to the one or morebuttons. Since the one or more buttons use a resistive technology ratherthan capacitive touch technology, contact with human skin is notrequired to activate the one or more buttons. The one or more buttonscan be activated even when a person is wearing gloves as is required foran operator in the mining environment.

Electrical detection signals from the one or more buttons are detectedand a corresponding signal is provided to the controller 40. Thecontroller 40 then performs the functions assigned to one or morebuttons based on the received signal. The one or more buttons include,for example, a stop button 432, an isolator button 436, one or morenavigational buttons 440, a home and/or select button 444, and/or one ormore control button banks 456A-F. The first control panel 420A includesa bolting light emitting diode (LED) 448 (e.g., a first LED) and adrilling LED 452 (e.g., a second LED). The second control panel 420Bincludes a three-color LED 460. In some embodiments, such as theembodiment illustrated in FIG. 23 , the one or more buttons include atext label describing the function of the button. In other embodiments,such as the embodiment illustrated in FIG. 24 , the one or more buttonsinclude an icon corresponding to the function of the button. The stopbutton 432 allows a user to stop an operation of the drill rig 10. Whenthe stop button 432 is pressed, the controller 40 ceases all mechanicalfunctions of the drill rig 10. The one or more navigational buttons 440and the home and/or select button 444 allow a user to navigate throughoptions on the display 424. The bolting LED 448 and the drilling LED 452are each, for example, multicolor LEDs provide a status indication ofthe bolting operation (e.g., a first operation) and the drillingoperation (e.g., a second operation) respectively.

The one or more control button banks 456A-F each include one or morecontrol buttons for manually controlling an operation of the drill rig10. For example, as illustrated by FIG. 23 , a first control button bank456A includes control buttons for controlling the drill head 34 and atimber jack. The first control button bank 456A includes a clockwiserotation button, a counterclockwise rotation button, a feed up button,and a feed down button. When the controller 40 determines that theclockwise rotation button is being pressed (that is, the controller 40receives an input to rotate the drill head 34 in a clockwise direction),the controller 40 controls an actuator (e.g., a motor) of the drill head34 to rotate the drill head 34 in a clockwise direction. When thecontroller 40 determines that the counterclockwise rotation button isbeing pressed (that is, the controller 40 receives an input to rotatethe drill head 34 in a counterclockwise direction), the controller 40controls an actuator of the drill head 34 to rotate the drill head 34 ina counterclockwise direction. When the controller 40 determines that thefeed up button is being pressed (that is, the controller 40 receives aninput to move the drill head 34 upward), the controller 40 controls anactuator of the drill head 34 to move the drill head 34 upward towardthe roof. When the controller 40 determines that the feed up button isbeing pressed (that is, the controller 40 receives an input to move thedrill head 34 downward), the controller 40 controls an actuator of thedrill head 34 to move the drill head 34 downward away from the roof. Thefirst control button bank 456A also includes a timber jack up and timberjack down buttons that similarly control the timber jack to move up(e.g., to support the roof) and down (e.g., after the boltingoperation). In some embodiments, the buttons provided in the firstcontrol button bank 456A are proportional input buttons such that theforce on the buttons dictates the speed of the corresponding operation.

A second control button bank 456B includes control buttons forcontrolling a position of the carousel 22, the loading arm 30, and thecarrier arm 130. The second control button bank 456B includes a carouselclockwise rotation button, a carousel counterclockwise rotation button,an arm to feed button, an arm from feed button, a washer loader upbutton, and a washer loader down button. When the controller 40determines that the carousel clockwise rotation button is being pressed(that is, the controller 40 receives an input to rotate the carousel 22in a clockwise direction), the controller 40 controls the actuator 46 torotate the carousel in a clockwise direction. When the controller 40determines that the carousel counterclockwise rotation button is beingpressed (that is, the controller 40 receives an input to rotate thecarousel 22 in a counterclockwise direction), the controller 40 controlsthe actuator 46 to rotate the carousel in a counterclockwise direction.When the controller 40 determines that the arm to feed button is beingpressed (that is, the controller 40 receives an input to move theloading arm 30 to the carousel 22), the controller 40 controls thesecond actuator 206 to move the loading arm 30 to the carousel 22. Whenthe controller 40 determines that the arm from feed button is beingpressed (that is, the controller 40 receives an input to move theloading arm 30 away from the carousel 22), the controller 40 controlsthe second actuator 206 to move the loading arm 30 away from thecarousel 22. When the controller 40 determines that the washer loader upbutton is being pressed (that is, the controller 40 receives an input toraise the carrier arm 130), the controller 40 controls the actuator 136to raise the carrier arm 130. When the controller 40 determines that thewasher loader down button is being pressed (that is, the controller 40receives an input to lower the carrier arm 130), the controller 40controls the actuator 130 to lower the carrier arm 130. In someembodiments, the buttons provided in the second control button bank 456Bare proportional input buttons such that the force on the buttonsdictates the speed of the corresponding operation.

A third control button bank 456C includes control buttons foropening/closing an arm gripper. When the controller 40 determines thatthe arm gripper open button is pressed (that is, the controller receivesan input to open the clamps 222), the controller 40 controls the clampactuators to open the clamps 222. When the controller 40 determines thatthe arm gripper close button is pressed (that is, the controllerreceives an input to close the clamps 222), the controller 40 controlsthe clamp actuators to close the clamps 222.

A fourth control button bank 456D includes a bolt button for beginning abolting operation (see, e.g., FIG. 31 ), and a resin button forbeginning a resin injection operation (see, e.g., FIG. 30 ). A fifthcontrol button bank 456E includes control buttons for selecting anautomation state of the drill rig 10. The fifth control button bank 456Eincludes a semi/full auto button for selecting a semi/full automationmode of the drill rig 10 (see, e.g., FIG. 28 ) and a pause/resume autobutton for pausing or resuming an automatic operation of the drill rig10. A sixth control button bank 456F includes buttons for controlling adrill operation of the drill rig 10. The sixth control button bank 456Fincludes a drill button for beginning a drill operation (see, e.g., FIG.29 ), plus (+) and minus (−) buttons to control the intensity or speedof the drilling operation, a water button to control a cooling waterflow for the drilling operation, and a boost button to provide a powerboost for the drilling operation. In some embodiments, the buttonsprovided in the sixth control button bank 456F are proportional inputbuttons such that the force on the buttons dictates the speed of thecorresponding operation.

The various control buttons of the control button banks 456A-F providecontrols for activating, deactivating, pausing, or resuming an automaticoperation of the drill rig 10. The various control buttons of thecontrol button banks 456A-F also provide controls for a manual controloperation of the drill rig 10. For example, in response to an errordetected during an automatic operation of the drill rig 10, the drillrig 10 may require an operator to manually control the drill rig 10 as afailsafe.

In some embodiments, various landmarks may be provided between thedifferent button banks 456A-F and around the one or more buttons so thatthe user can easily locate the button banks 456A-F based on touch. In amining environment, there may not always be sufficient light for anoperator to easily make out the different buttons. FIG. 23A illustratesone example of the landmarks provided on the control panel 420A. A firstlandmark 460 is provided between the first control button bank 456A andthe second control button bank 456B. The first landmark 460 may be anengraved landmark or a raised landmark such that a user may feel thefirst landmark 460 as the user moves their hand from the first controlbutton bank 456A to the second control button bank 456B. An engravedlandmark is a feature that is depressed into the surface membrane keypadand a raised landmark is a feature that is raised above a surface of themembrane keypad. A second set of landmarks 464 are provided around afirst button 468 and a second button 472 of the first control buttonbank 456A. In the example illustrated, the second set of landmarks 464are directional landmarks indicating upwards and downwards around thefirst button 468 and the second button 472 respectively. The second setof landmarks 464 may include engraved landmarks or raised landmarks suchthat the user may feel the second set of landmarks 464 as the user movestheir hand over the second set of landmarks 464. The first button 468 isa feed up button that is used to move a component upwards and the secondbutton 472 is a feed down button that is used to move a componentdownwards. The second set of landmarks 464 therefore indicate to a userthat the first button 468 and second button 472 are upward and downwardmovement buttons of the respective button bank 456A-F. A third landmark476 is provided around a third button 480. The third landmark 476 isalso a directional landmark indicating an upward direction, however, thethird landmark 476 is not provided as a set. Accordingly, the thirdlandmark 476 is provided to indicate that the corresponding button 480is a rotational button. In the example illustrated, the third button 480is a clockwise rotation button and a fourth button 484 is provided belowthe third button 480. The fourth button 484 is a counterclockwiserotation button. In some embodiments, a fourth set of landmarks may alsobe provided around buttons that are used for lateral movement. Thefourth set of landmarks are directional landmarks indicating a left andright directions on the control panel 420A. In some embodiments, one ormore of the control button banks 456A-F also include a bounding box 488to visually differentiate between the different buttons. Bounding boxesare also provided around each of the one or more buttons. In someembodiments, the intrinsically safe control panel 420 further includes aconnector that allows a connection of a second intrinsically safecontrol panel. The second intrinsically safe control panel 420 may beconfigured to control the drill rig 10 from a distance (for example,remotely or from a remote location). The connector may be a wirelessconnector or a wired connector. In embodiments wherein the connector isa wireless connector, the wireless connector may be a Wi-Fi connector, aBluetooth connector, a satellite connector, a cellular networkconnector, a radio transceiver, a combination thereof, or the like.

The display 424 is used to display a graphical user interface, such asthe function interface 500 illustrated in FIGS. 25-27B. FIG. 25illustrates a drilling function interface 500A. The drilling functioninterface 500A includes a drill view tab 502, a resin view tab 504, anda bolt view tab 506. The drilling function interface 500A furtherincludes a previous auto state indicator 508 for indicating a previousautomated task performed by the drill rig 10 while in as fully automaticmode, a current auto state indicator 510 for indicating a currentautomated task performed by the drill rig 10 while in as fully automaticmode, and a next auto state indicator 512 for indicating a nextautomated task performed by the drill rig 10 while in as fully automaticmode. The drilling function interface 500A also include an instrumentpanel 514 and a status panel 538 a.

The instrument panel 514 displays a feed pressure gauge 516 and a feedpressure target indicator 518, a rotational pressure gauge 520 and arotational pressure target indicator 522, an orientation index 524including a north/south degree value 526 and an east/west degree value528, a timber jack pressure gauge 530, a water flow rate gauge 532, anda water pressure gauge 534 including a selector button 536.

The status panel 538A displays information relating to an automateddrilling function, such as a target hole depth value 540, a current holedepth indicator 542, a feed speed indicator 544, a rotation directionindicator 546, a timber jack indicator 548, a carousel positionindicator 550, a drill steel indicator 552, a washer loader indicator554, a washer loader working position indicator 556, and washer loaderhome position indicator 558, and a top jaw reflex indicator 560.

FIG. 26A illustrates a resin function interface 500B at a first timeduring an automated resin function. The resin function interfaceincludes similar tabs and panels as the drill function interface 500A.The resin function interface 500B further includes a status panel 538B.The status panel 538B displays information relating to the automatedresin function, such as a resin inserter indicator 562, a resinindicator 564, a carousel index degree indicator 566, a loader armindicator 568, a mid-jaw indicator 570, and a top-jaw indicator 572.FIG. 26B illustrates the resin function interface 500B at a second timelater than the first time during the automated resin function. The resinfunction interface 500B remains mostly unchanged, with the exception ofthe resin indicator 564 and loader arm indicator 568 being shown indifferent positions on the status panel 538B. This indicates that theautomated resin operation was successful.

FIG. 27A illustrates a bolting function interface 500C at a first timeduring an automated bolting function. The bolting function interface500C includes similar tabs and panels as the drill function interface500A. The bolting function interface 500C also includes a status panel538C. The status panel 538C displays information relating to theautomated resin function, such as a drill steel pot indicator 574, aresin pot indicator 576, a bolt pot indicator 578, a dolly pot indicator580, and a bolt indicator 582. FIG. 27B illustrates the bolting functioninterface 500C at a second time later than the first time during theautomated bolting function. The bolting function interface 500C remainsmostly unchanged, with the exception of the bolt indicator 564 andloader arm indicator 568 being shown in different positions on thestatus panel 538C. This indicates that the automated bolting operationwas successful.

FIG. 28 is a flowchart illustrating an example method 600 for fullyautomated operation of the drill rig 10. In the example illustrated, themethod 600 includes receiving, at the controller 40, a full automationmode request (at block 606). For example, a user or operator of thedrill rig 10 may press the full/semi auto button from the button bank456F. In some embodiments, the request may be received from the centralcontroller 312. The method 600 includes automatically performing acalibration operation of calibrating one or more sensors of the drillrig 10 (at block 608). For example, the sensors may be the sensors 324of FIG. 19 . The calibration operation may include calibrating feedpressure of the actuators used for actuating various features of thedrill rig 10. The calibration operation may also include rotationpressure calibration. In some embodiments, the calibration operation maynot be performed for every instance of the method 600. The calibrationoperation may be performed at regular intervals, for example, afterevery tenth operation of the drill rig 10. The method 600 also includesautomatically performing a drilling operation (at block 610) in responseto receiving the full automation request. The drilling operation mayinclude controlling the drill rig 10 to drill a hole into a surface of aworking area 294. The drilling operation is described further withrespect to FIG. 29 . The method 600 further includes automaticallyperforming a resin injection operation (at block 612) subsequent to thedrilling operation. For example, the resin injection operation mayinclude injecting resin into the hole drilled into a surface of theworking area 294. The resin injection operation is described furtherwith respect to FIG. 30 . The method 600 also includes automaticallyperforming a bolting operation (at block 614) subsequent to the resininjection operation. For example, the bolting operation may includeinserting a bolt into the hole drilled into a surface of the workingarea 294. The bolting operation is described further with respect toFIG. 31 . Following the bolting operation, the drill rig 10 may enter astand-by mode until the drill rig 10 is moved to the next boltinglocation. While performing any of the blocks 608-614, if the drill rig10 encounters an error, the drill rig 10 may exit full automation modeand instruct a user to manually perform the next step. This process isdetailed further in FIG. 32 .

FIG. 29 is a flowchart illustrating an example method 800 forautomatically performing a drilling operation. The blocks described inmethod 800 may be performed in a different order than described herein.The method 800 begins when the drill rig 10 receives a control signal tobegin an automatic drilling operation (e.g., at block 610 of FIG. 28 ).In the example illustrated, the method 800 includes rotating, using theactuator 46, the carousel 22 to a drill loading position (at block 802).The drill loading position is a position in which the drill bit 18A isaligned with the loading arm 30 (for example, as shown in FIG. 16B). Thecontroller 40 controls the actuator 46 to rotate the carousel 22 suchthat the drill bit 18A is in the loading position based on the rotaryposition signals received from the encoder 50. Specifically, thecontroller 40 continues to rotate the carousel 22 using the actuator 46until the encoder 50 indicates that the carousel is in the drill loadingposition. The method 800 also includes securing the drill bit 18A fromthe carousel 22 to the loading arm 30 for loading the drill bit 18A tothe drill head 34 (at block 804). The controller 40 controls the clampactuators to close the clamps 222 around the drill bit 18A as shown inFIG. 16D. The controller 40 determines that the drill bit 18A is alignedwith the loading arm 30 such that the clamps 222 can grasp the drill bit18A based on the signals received from the sensor 230.

The method 800 also includes loading, using the washer loader assembly110, the washer 114 on the drill bit 18A (at block 806). The controller40 controls the washer loader assembly 110 as discussed with respect toFIGS. 9-12 to load the washer 114 on the drill bit 18A. The controller40 controls the actuator 138 to place the carrier arm 130 on the stackof washers 122 as shown in FIGS. 16B and 16C. The magnet 182 under thecarrier arm 130 secures a single washer 114. Once the washer 114 issecured to the carrier arm 130, the controller 40 controls the actuator138 to raise the carrier arm 130 with the washer 114. The controller 40aligns the loading arm 30 with the carrier arm 130 such that when theloading arm 30 is raised the drill bit 18A passes through an opening ofthe washer 114 and the carrier arm 130 as shown in FIGS. 16D and 16E.The controller 40 controls the first actuator 206 to raise the loadingarm 30 such that the drill bit 18A passes through the opening of thewasher 114.

The method 800 includes loading, using the loading arm 30, the drill bit18A in the drill head 34 (at block 808). The controller 40 controls thesecond actuator 210 to rotate the loading arm such that drill bit 18A isabove the drill head 34. The controller 40 then controls the firstactuator 206 to lower the drill bit 18A into the drill head 34. In someembodiments, rather than lowering the loading arm 30, the drill head 34may be raised to receive the drill bit 18A. That drill head 34 mayinclude a chuck that is controlled by the controller 40 to secure thedrill bit 18A to the drill head 34. Once the drill bit 18A is loadedinto the drill head 34, the controller 40 rotates the loading arm awayfrom the drill head 34 using the second actuator 206. At the same timeas being loaded into the drill head 34, the drill bit 18A is also loadedinto the top plate 198. The top plate 198 is axially aligned with thedrill head 34 such that the drill bit 18A is received in the drill head34 and the top plate 198 at the same time. When the loading arm 30 ismoved away from the drill head 34, the washer 114 slides down the drillbit 18A and settles on the top plate 198.

The method 800 includes drilling, using the drill head 34, the drill bit18A into the working surface 294 to create a drill hole (at block 810).The controller 40 translates the drill head 34 and the top plate suchthat the top plate 198 and the washer 114 are in contact with theworking surface 294 as shown in FIG. 161 . The controller 40 operatesthe drill head 34 to drill a hole in the working surface 294 using thedrill bit 18A as shown in FIG. 16J.

The method 800 also includes securing the drill bit 18A from the drillhead 34 to the loading arm 30 for unloading the drill bit 18A (at block812). The controller 40 retracts the drill head 34 to a home positionafter drilling. The controller 40 controls the second actuator 210 tomove the loading arm 30 to the drill head 34 and controls the clampactuator 225 to close the clamps 222 around the drill bit 18A. The drillhead 34 is disconnected from the drill bit 18A, for example, by rotatinga chuck of the drill head 34. The method 800 further includes unloading,using the loading arm 30, the drill bit 18A to the carousel 22 (at block814). The controller 40 controls the second actuator to move the loadingarm 30 from the drill head 34 to the carousel 22. The controller 40controls the clamp actuator 225 to open the clamps 222 such that drillbit 18A is placed back in the carousel 22 as shown in FIG. 16O. Thedrill rig 10 may wait for a control signal to proceed to the nextautomatic operation (for example, the automatic resin injectionoperation or the automatic bolting operation). While performing any ofBLOCKS 802-814, if the drill rig 10 encounters an error, the drill rig10 may exit full automation mode and instruct a user to manually performthe next step. This process is detailed further in FIG. 32 .

FIG. 30 is a flowchart illustrating an example method 900 for performingan automatic resin injection operation. The blocks described in method900 may be performed in a different order than described herein. Themethod 900 begins when the drill rig 10 receives a control signal tobegin an automatic resin injection operation (e.g., at block 612 of FIG.28 ). In the example illustrated, the method 900 includes rotating,using the actuator 46, the carousel 22 to the resin cartridge loadingposition (at block 902). The resin cartridge loading position is aposition in which the resin cartridge 18B is aligned with the loadingarm 30 (for example, as shown in FIG. 17A). The controller 40 controlsthe actuator 46 to rotate the carousel 22 such that the resin cartridge18B is in the loading position based on the rotary position signalsreceived from the encoder 50. Specifically, the controller 40 continuesto rotate the carousel 22 using the actuator 46 until the encoder 50indicates that the carousel is in the resin cartridge loading position.The method 900 also includes securing the resin cartridge 18B from thecarousel 22 to the loading arm 30 for loading the resin cartridge 18B tothe drill head 34 (at block 904). The controller 40 controls the clampactuators to close the clamps 222 around the resin cartridge 18B. Thecontroller 40 determines that the resin cartridge 18B is aligned withthe loading arm 30 such that the clamps 222 can grasp the resincartridge 18B based on the signals received from the sensor 230.

The method 900 includes loading, using the loading arm 30, the resincartridge 18B in the drill head 34 (at block 906). The controller 40controls the second actuator 210 to rotate the loading arm such thatresin cartridge 18B is above the drill head 34. The controller 40 thencontrols the first actuator 206 to lower the resin cartridge 18B intothe drill head 34. In some embodiments, rather than lowering the loadingarm 30, the drill head 34 may be raised to receive the resin cartridge18B. Once the resin cartridge 18B is loaded into the drill head 34, thecontroller 40 rotates the loading arm 30 away from the drill head 34using the second actuator 206.

The method 900 includes injecting, using the resin cartridge 18B, resininto the hole drilled in the working surface 294 (at block 908). Thecontroller 40 translates the drill head 34 such that a resin opening ofthe resin cartridge 18B is inserted into the top plate 198 as shown inFIG. 17E. The controller 40 operates the drill head 34 to activate theresin cartridge 18B and to inject the resin in the hole drilled in theworking surface 294.

The method 900 also includes securing the resin cartridge 18B from thedrill head to the loading arm 30 for unloading the resin cartridge 18B(at block 910). The controller 40 retracts the drill head 34 to a homeposition after resin injection. The controller 40 controls the secondactuator 210 to move the loading arm 30 to the drill head 34 andcontrols the clamp actuator 225 to close the clamps 222 around the spentresin cartridge 18B. The method 900 further includes unloading, usingthe loading arm 30, the spent resin cartridge 18B to the carousel 22 (atblock 912). The controller 40 controls the second actuator 210 to movethe loading arm 30 from the drill head 34 to the carousel 22. Thecontroller 40 controls the clamp actuator 225 to open the clamps 222such that resin cartridge 18B is placed back in the carousel 22 as shownin FIG. 17H. In some embodiments, the loading arm 30 may unload thespent resin cartridge 18B to a different location. The resin injectionoperation then ends. The drill rig 10 may wait for a control signal toproceed to the next automatic operation (for example, the automaticbolting operation). While performing any of BLOCKS 902-912, if the drillrig 10 encounters an error, the drill rig 10 may exit full automationmode and instruct a user to manually perform the next step. This processis detailed further in FIG. 32 .

FIG. 31 is a flowchart illustrating an example method 1000 forperforming an automatic bolting operation. The blocks described inmethod 100 may be performed in a different order than described herein.The method 1000 includes rotating, using the actuator 46, the carousel22 to a bolt loading position (at block 1002). The bolt loading positionis a position in which the bolt 18C is aligned with the loading arm 30(for example, as shown in FIG. 18A). The controller 40 controls theactuator 46 to rotate the carousel 22 such that the bolt 18C is in theloading position based on the rotary position signals received from theencoder 50. Specifically, the controller 40 continues to rotate thecarousel 22 using the actuator 46 until the encoder 50 indicates thatthe carousel 22 is in the bolt loading position. The method 1000 alsoincludes securing the bolt 18C from the carousel 22 to the loading arm30 for loading the bolt 18C to the drill head 34 (at block 1004). Thecontroller 40 controls the clamp actuators to close the clamps 222around the bolt 18C. The controller 40 determines that the bolt 18C isaligned with the loading arm 30 such that the clamps 222 can grasp thebolt 18C based on the signals received from the sensor 230.

The method 1000 includes loading, using the loading arm 30, the bolt 18Cin the drill head 34 (at block 1006). The controller 40 controls thesecond actuator 210 to rotate the loading arm such that bolt 18C isabove the drill head 34. The controller 40 then controls the firstactuator 206 to lower the bolt 18C into the drill head 34. In someembodiments, rather than lowering the loading arm 30, the drill head 34may be raised to receive the bolt 18C. Once the bolt 18C is loaded intothe drill head 34, the controller 40 rotates the loading arm 30 awayfrom the drill head 34 using the second actuator 206.

The method 1000 includes aligning, using the drill head 34, the bolt 18Cwith the drill hole in the working surface 294 (at block 1008). Thecontroller 40 raises the drill head 34 such that the bolt 18C isreceived in the top plate 198 and aligned with the drill hole in theworking surface 294. The top plate 198 secures the bolt 18C such thatthe bolt 18C can be dismounted from the drill head 34. Once the bolt 18Cis secured by the top plate, the controller 40 lowers the drill head 34away from the bolt 18C to the home position. The method 100 includesrotating, using the actuator 46, the carousel 22 to an adapter loadingposition (at block 1010). The adapter loading position is a position inwhich the adapter 18D is aligned with the loading arm 30 (for example,as shown in FIG. 18F). The controller 40 controls the actuator 46 torotate the carousel 22 such that the adapter 18D is in the loadingposition based on the rotary position signals received from the encoder50. Specifically, the controller 40 continues to rotate the carousel 22using the actuator 46 until the encoder 50 indicates that the carouselis in the adapter loading position. The method 1000 also includessecuring the adapter 18D from the carousel 22 to the loading arm 30 forloading the adapter 18D to the drill head 34 (at block 1012). Thecontroller 40 controls the clamp actuators to close the clamps 222around the adapter 18D. The controller 40 determines that the adapter18D is aligned with the loading arm 30 such that the clamps 222 cangrasp the adapter 18D based on the signals received from the sensor 230.In some embodiments, the blocks 1008-1012 may be performedsimultaneously with blocks 1004 and 1006.

The method 1000 includes loading, using the loading arm 30, the adapter18D in the drill head 34 (at block 1014). The controller 40 controls thesecond actuator 210 to rotate the loading arm such that adapter 18D isabove the drill head 34. The controller 40 then controls the firstactuator 206 to lower the adapter 18D into the drill head 34. In someembodiments, rather than lowering the loading arm 30, the drill head 34may be raised to receive the adapter 18D. Once the adapter 18D is loadedinto the drill head 34, the controller 40 rotates the loading arm 30away from the drill head 34 using the second actuator 206. The method1000 further includes driving, using the drill head 34 and the adapter18D, the bolt 18C into the working surface 294 (at block 1016). Thecontroller 40 controls the drill head 34 to couple the adapter 18D tothe bolt 18C. Once the adapter 18D is coupled to the bolt 18C, thecontroller 40 controls the drill head 34 to insert the bolt 18C into thedrill hole in the working surface 294. The bolt 18C is held in place inthe drill hole with the resin previously injected into the drill hole.The controller 40 lowers the drill head 34 to the home position.

The method 1000 also includes securing the adapter 18D from the drillhead 34 to the loading arm 30 for unloading the adapter 18D (at block1018). The controller 40 controls the second actuator 210 to move theloading arm 30 to the drill head 34 and controls the clamp actuator 225to close the clamps 222 around the adapter 18D. The method 1000 furtherincludes unloading, using the loading arm 30, the adapter 18D to thecarousel 22 (at block 1020). The controller 40 controls the secondactuator 210 to move the loading arm 30 from the drill head 34 to thecarousel 22. The controller 40 controls the clamp actuator 225 to openthe clamps 222 such that adapter 18D is placed back in the carousel 22as shown in FIG. 18M. The automatic bolting operation then ends. Thedrill rig 10 may wait for a control signal to proceed to the nextautomatic operation (for example, restarting the full automation mode).While performing any of blocks 1004-1020, if the drill rig 10 encountersan error, the drill rig 10 may exit full automation mode and instruct auser to manually perform the next step. This process is detailed furtherin FIG. 32 .

FIG. 32 is a flowchart illustrating an example method 1100 of performingan error-handling operation of the drill rig 10. While performing anyautomatic operation (i.e., any of the blocks 608-614 of FIG. 28 , blocks802-814 of FIG. 29 , blocks 902-912 of FIG. 30 , and blocks 1002-1020 ofFIG. 31 ), the drill rig 10 may encounter an error. The drill rig 10 mayenter a failsafe operation mode to perform an error-handling operationin response to the error. The method 1100 includes performing anyautomatic operation of the drill rig 10 while in full automation mode(at block 1102). The automatic operation may be any of the blocks608-614 of FIG. 28 , blocks 802-814 of FIG. 29 , blocks 902-912 of FIG.30 , and blocks 1002-1020 of FIG. 31 . The automatic operation may alsobe another operation not listed above. The method also includesdetermining, using the controller 40, whether an error has occurred (atblock 1104) during one of the automatic operations (e.g., the automaticdrilling operation, the automatic resin injection operation, and theautomatic bolting operation). The error may be detected by the sensors324 of the drill rig 10, a length of time since the last step wasperformed, or by some other means. When no error is detected, the method1100 returns to block 1102 (e.g., the drill rig 10 proceeds to the nextautomatic operation). In response to detecting the error, the method1100 includes directing a user to manually perform an operation (atblock 1106). For example, the controller 40 displays an alert on thedisplay 424 indicating that an error has occurred during operation. Insome embodiments, the controller 40 may display the error status usingthe multi-color LEDs 448 and 452. On the display 424, the controller 40may provide an instruction for a user to manually complete the remainingoperation, for example, using one of the display screens as shown inFIGS. 25-27B.

The method 1100 include receiving, via the control panel 420, user inputcorresponding to the operation (at block 1108). As discussed above withrespect to FIGS. 23-24 , the user may control the drill rig 10 using oneor more buttons provided on the control panel 420. Specifically, theuser presses the one or more buttons to continue the present operationof the drill rig 10. The method 100 also includes performing, using thecontroller 40, the operation based on user input (at block 1110). Asdiscussed above, the controller 40 receives the user input from thecontrol panel 420. The controller 40 then controls the correspondingcomponent based on the user input.

The method 1100 includes determining, using the controller 40, whetherthe error is resolved (at block 1112). The controller 40 may determinewhether the error is resolved based on the sensors 324. When the erroris not resolved, the method 1100 returns to block 1108 to continuemanual operation. When the error is resolved, the method 1100 includesgenerating, using the controller 40, an alert indicating that the drillis ready for automated operation (at block 1114). For example, thecontroller 40 displays an alert on the display 424 indicating that theerror has been resolved. In some embodiments, the controller 40 maydisplay the error status using the multi-color LEDs 448 and 452.

The method 110 includes receiving, via the control panel 420, an inputto resume automated operation (at block 1116). For example, the user maypress the full automation button on the control panel 420A. The method1100 further includes resuming, using the controller 40, automatedoperation of the drill rig (at block 1118). The automated operation mayinclude one of the drilling operation, the resin injection operation,and the bolting operation. The controller 40 may resume operation from apoint where manual operation was stopped after detecting the error.

Therefore, embodiments described herein provide systems and methods forperforming fully automatic operations of a drill rig, such as a bolter.Although aspects have been described in detail with reference to certainpreferred embodiments, variations and modifications exist within thescope and spirit of one or more independent aspects as described.

What is claimed is:
 1. A drilling and bolting rig comprising: a carouselrotatable about a carousel axis and including a plurality of stationsconfigured to support a plurality of consumables; one or more actuatorsconfigured to rotate the carousel about the carousel axis; a positionsensor coupled to the carousel; and an electronic processor coupled tothe one or more actuators and the position sensor, the electronicprocessor configured to detect, using the position sensor, a rotationalposition of the carousel; rotate, using the one or more actuators, thecarousel based on the rotational position of the carousel.
 2. Thedrilling and bolting rig of claim 1, wherein the position sensor is amagnetic rotary encoder.
 3. The drilling and bolting rig of claim 1,wherein the position sensor includes a Hall-sensor.
 4. The drilling andbolting rig of claim 3, wherein the position sensor is an intrinsicallysafe position sensor and includes an encoder housing, wherein theencoder housing is fixed to the carousel such that the Hall-sensorextends into the carousel and is in close proximity to a magnet attachedto the carousel.
 5. The drilling and bolting rig of claim 4, wherein theposition sensor is exposed from the encoder housing and placed in closecontact with the magnet.
 6. The drilling and bolting rig of claim 5,wherein the position sensor is provided outside a periphery of theencoder housing.
 7. The drilling and bolting rig of claim 5, wherein theposition sensor extends into the housing of the carousel.
 8. Thedrilling and bolting rig of claim 4, wherein an air-tight seal isprovided between the encoder housing and the housing of the carousel. 9.The drilling and bolting rig of claim 4, wherein the magnet extends intothe encoder housing.
 10. The drilling and bolting rig of claim 4,further comprising a Universal Asynchronous Receiver-Transmitter (UART)configured to integrate the position sensor with other components of thedrilling and bolting rig.
 11. A control panel for a drill rig of anautomatic bolter comprising: a keypad including an overlay; a pluralityof buttons provided on the keypad and configured to control variousfunctions of the drill rig; a plurality of force sensing resistormaterial corresponding to the plurality of buttons provided below theoverlay, wherein a drop in resistance of a force sensing resistormaterial of the plurality of force sensing resistor material correspondsto a force applied to the corresponding button of the plurality ofbuttons; and a display and a speaker provided on the keypad, wherein theplurality of buttons are divided between a plurality of control buttonbanks, each control button bank of the plurality of control button bankscorresponding to a particular component of the drill rig.
 12. Thecontrol panel of claim 11, wherein the overlay has a thickness between0.15 millimeters (mm) and 3 mm.
 13. The control panel of claim 11,further comprising a first light emitting diode (LED) and a second LEDcorresponding to a first operation and a second operation of the drillrig, the first LED providing a status indication of the first operation,and the second LED providing a status indication of the secondoperation, wherein the first LED and the second LED are multicolor LEDs.14. The control panel of claim 11, further comprising: a first landmarkprovided between a first control button bank and a second control buttonbank of the plurality of control button banks.
 15. The control panel ofclaim 14, further comprising: a second set of landmarks provided arounda first button and a second button of the first control button bank. 16.The control panel of claim 15, further comprising: a third landmarkaround a third button of the first control button bank; and a fourthbutton provided below the third button without a landmark.
 17. Thecontrol panel of claim 16, wherein the first landmark, the second set oflandmarks and the third landmark are raised landmarks.
 18. The controlpanel of claim 16, wherein the first landmark, the second set oflandmarks and the third landmark are engraved landmarks.
 19. The controlpanel of claim 16, wherein the first button is provided above a secondbutton, wherein the second set of landmarks are directional landmarksindicating upwards and downwards directions around the first button andthe second button respectively, wherein the first button and the secondbutton control an upward and downward movement respectively of acomponent of the drill rig.
 20. The control panel of claim 16, whereinthe third landmark is a directional landmark indicating an upwardsdirection around the third button, wherein the third button and thefourth button control a clockwise and counterclockwise rotationrespectively of a component of the drill rig.
 21. The control panel ofclaim 14, further comprising a bounding box provided around the firstcontrol button bank.
 22. The control panel of claim 11, furthercomprising a connector that allows a connection of a second controlpanel configured to control the automatic bolter from a distance.